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Bryan Steam LLC, 783 North Chili Avenue, Peru, IN

1. wel Figure 9 Pilot Spark Igniter Assembly NO OT boah Spark grounding screw Pilot igniter gas orifice 49 Drill Shell body Gland nut Igniter electrode Brass bushing Gas inlet fitting Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 1 7 Triple Flex Left Flue Collector View Figure 10 Triple Flex Left Flue Collector View i O00 NIOH OTE O 3 Lower drum cleanout and inspection opening Furnace tube access panel Convection tube access panel Primary air to air exchanger access cover ASME name plate stamping Combustion air blower 3 Upper drum cleanout and inspection ASME Safety relief valve Air filter 20 x 25 This filter is a polyester coated fiberglass The frame is made of fiberboard and has two tin plated steel grills one bonded to each side as well as sealed corners to prevent dust leakage Filters are marked with size and airflow direction Actual length and width are 38 less than trade size shown Filters meet UL Class 2 flame retardance requirements Maximum temperature is 180 F
2. warnine During the first 10 seconds of this process the automatic gas valves should not have opened or been energized If any of the automatic gas valves are energized or open at this point correct the problem immediately 2 3 6 Pilot Adjustment Adjust the pilot gas pressure between 3 5 iwc and 4 iwc The pilot flame signal can be observed from the status page paragraph 2 2 5 The minimum flame signal is 8 volts The flame signal can vary between 4 volts and 15 volts A flame signal closer to 15 volts is preferred Observe the pilot flame through the flame observation port Figure 5 item 4 The pilot should appear stable A stable pilot will not flicker on and off Recycle the boiler as many times as needed to establish a good pilot If the pilot fails to light refer to troubleshooting paragraph 2 4 for further help warnine During pilot adjustment leave the manual main gas cock Figure 7 item 4 closed NOTE Pilot gas pressures in excess of the recommended will lead to the formation of carbon hairs that will ground out the pilot igniter causing a safety shutdown 2 3 7 Initial Light Off Open the manual main gas cock Figure 7item 4 Clear the lockout fault paragraph 2 2 10 and allow the burner to cycle and attempt to light off If the main flame fails to light the low fire displacement of the pressure regulating actuator Figure 7 item 2 may need to be incr
3. Power up the boiler see paragraph 2 2 1 Navigate to the Operation Page Figure 27 Select the burner switch to toggle the burner to the off state Navigate to the Firing Rate Control Page paragraph 2 2 14 Select the Manual in Run option and enter the light off RPM from in the Manual Firing Rate box This will prevent the burner from ramping up to high fire after the flame stabilization period Navigate to the Annunciation Page Figure 28 All load control inputs and interlocks should be in the on state with the exception of the air flow switch The air flow switch will close when the burner is commanded to start Correct any problem indicated Refer to trouble shooting paragraph 2 4 for further help Navigate to the Operation Page Figure 27 The boiler is now prepared to be placed in the on state by toggling the burner switch to on 2 3 4 Operating Data Label Figure 48 is provided on the side of the control panel to record the startup operating data of the boiler This information will be used for future reference Figure 12during maintenance periods or for troubleshooting Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 35 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Triple Flex Operatin
4. Touch unit in time to change it 4 Ok l Cancel Figure 31 System Date amp Time Set the date by selecting the date with the drop down month display Select the hour minutes or am pm part of the time and use the left and right arrow keys to set the current time Select the OK button when finished 2 2 16 Calibrate Touch Screen gt Setup gt Display Diagnostics gt Calibrate Screen WW Display Diagnostics Version 1 1 Memory 15 1MB out of 38 4MB available Build 47 USB Status NOT FOUND COM 1 Enabled Bytes Packets Rate bps Za Receive _ 27405024 895387 1184 Transmit O 7163147 895395 256 Pause COM 2 Enabled Bytes Packets Rate bps x Clear Receive _ 0 0 0 Transmit 0 0 0 Pause Calibrate Audio Video Screen Display Screen Test Test Snapshot Reset Figure 32 Display Diagnostics Occasionally the touch screen will need to be calibrated When the screen is touched in a spot and unexpected results occur this is a good indication that the display needs to be calibrated To calibrate the touch screen select the Calibrate Screen button and follow the on screen directions Try using a stylus of some kind if the problem persists The eraser end of a pencil or the blunt end of a pen can be used as a good stylus 2 2 17 Reset Reboot Display el Setup gt Display Diagnostics gt Display Reset Are you sure you want to RESET the disp
5. All cover plates enclosures and guards must be in place at all times except during maintenance and servicing 3 1 Draining The System A clean neutral hot water system should not be drained except for an emergency or when unavoidable for servicing of equipment See Section 1 10 for water treatment required when refilling 3 2 External Fire Side Cleaning Purpose Carbon soot is an insulator and corrosive The heating surfaces of a boiler must be kept free from soot accumulation to keep the boiler operating at its highest efficiency and to avoid damage from corrosion Soot removal If the yearly inspection of the boiler tube surfaces reveals a build up of soot or rust usually due to condensation the tubes should be thoroughly brushed Tube cleaning brushes are available from Bryan Steam To inspect and if necessary clean the tube surfaces and flue collector first remove the tube access panels Examine the exterior of the tubes for evidence of soot or rust Using a flashlight carefully look between the tubes There should be an unobstructed opening between all tubes and the top surfaces of the tube must be free from soot accumulation Also inspect the interior of the flue collector Brush or vacuum the soot from all surfaces Be sure to cover Triple Flex burner with a protective cover during cleaning to prevent soot from falling onto it If the buildup of soot is appreciable the flue gas
6. 3 4 Suggested Maintenance Schedule ENEE 46 Section 4 Lead Lag ciesacss scntccteccesseseccceseesecessete ccsececscuescece coy ceuncdoscese EES cove coceoucucesecdeuceteacodcenedseseuavenecen 47 4 1 Lead Lag Parameters raana a Danana raaa aaa E aa Aaaa aa E Daaa SEAN 48 4 2 Lead Lag Sequence of Operatof at Ed AE ae ae en el a a ena EE 48 4 3 Lead Lag Communication ENEE 48 4 4 System Wiring HOOKUP eesessesssesssecsesseeseeeseeseesneesseeseesseeseesseesseeseessecaeesseesesseeaeeseesseeseeeaeestesneeseeatesaeentenseesseeaes 57 Tables Tabl tiMinimu m Ber EE 2 Table 2 Electrical Requirements doneras aan A AR E e E ER EAE EEEE S EE AE AT 4 Tabl e 3 Sound Pressure Heatlnge oeet eguekteik Sege aa astana aE aAa ERER aen Ga E Anaa ed 5 Table 4 Boiler Draft and Combustion Air Requirements cccccccceeeeeseeceeeeeceneeeeaeseeaeeseeeeesaeeeeaeeeeneeees 5 Table 5 Water Flow Rates for Variable Primary Dumping 5 Table 6 Water Flow Rates for Primary Secondary PUMPING ccceeeeeceeeeeeeeeeeeaeeeeeeeseeeeeseaeeeeaeeeeneeees 6 Table 7 A T Increase for Glycol Systems 6 Table 8 Recommended Feed Water Limits 0 eeeccceeeeneeeeeeeneeeeeeeaeeeeeeeaeeeeetaaeeeeeeaaeeeeesaeeeeeeaeeeeeenaeeeeneaa 13 Table 9 Water Flow Switch Settings cccccccecsceceeeeeceeeeeeeeeceeeeecaeeesaaeeeeaeeseeeeesaaeeesaaesseeeeseaeeeseaeeseeeeeenees 17 Table 10 Gas Limiting Orifice Rough Settings c ccccceeceeeeeeeeecene
7. Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 25 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 establishing period For 2 2 11 Operation Page example an elapsed time of 2 4 seconds would indicate a pilot failure S First Out For a interlock ILK lockout gt amp gt Operation this is the first device in the string of interlocks that ALI Dee E opened This would be the S SE Burner state Standby first item to troubleshoot the Burer erable on failure Demand Central Heat Center box A list of items and there state deeg Firing rate C orm when the failure occurred KE E Can be very helpful in GER Home et ee determining what was happening at the time of failure 8 _ 06 25 12 2 56 38 PM Cycle 40 Hours 3 06 25 67 ILK OFF a 25 State Run Timer 4 mins 50 secs d First Out Low Water n Pump A OFF x Pump B OFF Blower HSI ON External ignition OFF Pilot valve OFF Main valve OFF Alarm OFF Air Flow Switch OFF E 6 25 12 Ok J J Figure 26 Lockout Details 3 01 29 PM Use the following key sequence to clear a lockout and reset the boiler from the main display as an alternative to the manual rest push button Figure 3 item 7 DER Info Bar gt Lockouts gt Clear L
8. 2 27 2015 Revision 3 temperature Follow these same instructions to reset the Output high limit setpoint back to 200 F 2 2 25 Modbus Communication BMS Modbus RTU is connected to terminals 6 7 and 8 that are located on the J3 header of the WD857 PCB board Refer to Figure 49 for reference wiring If any other communication protocol is needed then the Bryan Universal Communication Gateway is required The Modbus register map and other related information can be found in Honeywell s R7910A1027 product manual or for an abbreviated points list refer to the Bryan Universal Communication Gateway manual 2 3 Boiler Commissioning NOTE All of the installation instructions found in section 7 must be completed before commissioning the boiler warnine The following procedures must be followed carefully before putting the boiler in operation Failure to do so will present severe hazards to equipment operating personnel and building occupants 2 3 1 Modulation Figure 47 Air Gas Ratio Tappings Modulation on the Triple flex boiler is accomplished with air gas ratio control The system consists of two major components a blower Figure 10 item 6 and a regulating gas valve Figure 7 item 3 The blower is variable speed and provides combustion air to the burner The blower rpm is controlled by a PWM pulse width modulation signal The PWM signal incre
9. burner on off option is used Bryan Steam Central Heat Configuration Modulation gt Modulation sensor Outlet sensor Modulation rate source Local P gain 50 I gain 10 D gain 0 Hysteresis step time 0 sec Figure 37 Central Heat Configuration Modulation Page Change the Modulation Rate Source parameter to the desired setting shown in the table 2 2 22 Central Heat Configuration ER CONFIGURE gt CH CENTRAL HEAT CONFIGURATION S2 J8 6 4 20mA with sensor The boiler will turn off via the local set point setting as shown is Figure 37 H D Cie Ger t D D ai Central Heat P CH enable Enabled Demand switch Modulation sensor only CH has priority over Lead Lag No Figure 38 Central Heat Configuration Central Heat Page S2 J8 6 4 20mA and Modulation Rate Source burner on off The boiler will not turn off unless a remote start on off command contact is opened between terminals 5 amp 6 or terminals 5 amp 7 CH enable Enable Disable Central Heating Loop Sensor for Central Heat demand Demand switch Modulation Sensor only Sensor amp STAT terminal Sensor amp Remote Stat LCI amp Sensor CH has priority over Lead Yes Lag No kel gl Geritedl Hout Geer EE D D ai Setpoint P Setpoint source Local Setpoint 180 F Time of day setpoint 16
10. 52 1 gom 46 1 gpm Table 9 Water Flow Switch Settings Low Water Cutoff Manual Reset Probe Type Combustion air flow switch An airflow switch is provided to prove that air is being provided to the burners before main flame can be established The airflow switch can be adjusted by turning the screw Figure 8 item A clockwise to increase the pressure setting and counter clockwise to decrease Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 17 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 the pressure setting The switch will open on pressure drop When the blower is running there should be continuity between the common and the normally open contacts Figure 8 item B and C When the blower is interrupted the switch should open and cause a safety shutdown Figure 8 Air Flow Switch 18 26 High burner air pressure switch manual reset This switch will trip when the air pressure in the burner rises above the set point indicating that the burner has become plugged with dust or other foreign matter Gas and air mixer assembly Main 3 phase and single phase power connection and fuse block Control circuit transformer 120 and 24 volt ac fuses 24 volt ac relay SOLA hydronic and flame supervision control L
11. 5F 68 40F 11F Table 6 Water Flow Rates for Primary Secondary Pumping 1 5 4 3 Water Flow Rates Constant Volume Primary Pumping Systems A constant volume primary pumping system shall be sized so that the flow rate specified in Table 6 can be maintained through each Triple Flex connected to the system 1 5 4 4 Water Flow Rates for Glycol For glycol systems the A T in Table 5 and Table 6 will increase as specified in Table 7 Glycol Concentration AT Percent Increase 50 24 30 14 Table 7 A T Increase for Glycol Systems 1 6 Combustion Air Supply System For proper combustion it is necessary to provide the boiler room with appropriate openings for fresh air supply Temporary air intakes such as windows and doors should be avoided since they may be closed In addition to air needed for combustion sufficient air must be supplied for ventilation as well as other air consuming equipment that may be present in the boiler room Often when personnel are working in the boiler room combustion air openings are closed due to the temperature of the outside air THIS MUST BE AVOIDED AT ALL COSTS Provisions should be made to heat the outside combustion air if necessary for personnel comfort Positive means for supplying an ample amount of outside air allowing for the complete combustion of the gas must be provided Movable combustion air dampers automatic or manually
12. BOILER 2 BOILER 4 GROUND DATA DATA POL DN MANAGEMENT ODBUS RTU Erysth Steer LLC vrus veng FR nman Pi fh Steer LLC rus veng ra oten PCB WD 857 IN OUT e BOILER 3 BOILER 1 10 Dk TERM RESISTER Ay asp Steen LLC Tr bee veng PE ote Pryor Steer LLC Ta veng rt tem PCB lt WD 857 PCB WD 857 gt Figure 49 Multi Boiler Field Wiring Condensate 3 7 16 19 Trap 3 16 19 alarm 24 Decibel Levels 5 CO Ctra 31 53 burner 3 6 8 11 14 17 18 20 22 31 32 33 53 57 58 62 filter 10 19 firing rate 25 26 27 32 33 46 57 59 60 61 Fuel Air Ratio 30 Combustion 2 3 5 6 7 8 9 15 17 18 19 31 32 33 39 41 53 Air 2 5 6 7 8 9 15 31 Requirements 5 Chamber 17 31 39 41 ILK Interlocks 26 36 38 40 49 Readings 32 33 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 57 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 lockout 15 20 24 25 26 32 35 37 38 39 40 41 43 46 50 Louvers 6 8 Modulation 21 26 29 31 32 33 37 47 50 58 Oxygen Levels 12 18 31 32 33 Setpoint 21 22 28 29 30 44 47 48 57 59 60 61 Remote 29 59 Tubes Convection 16 Furnace 16 Water Quality 12 Treatment 11 12 53 Bryan Steam
13. F Outlet high limit Enabled dual sensor safety Outlet high limit response Lockout Outlet high limit setpoint 200 F THIS PARAMETER REQUIRES SAFETY VERIFICATION Figure 44 High Limits Menu To change the high limit setpoint touch the 200 F in the outlet high limit setpoint parameter Ajo je fe DHV 200 a DH 200 e oF ao r safety Outld olla 2 3 4 Ou Si Can SES E OK Cancel Delete Clear Figure 45 Outlet high limit setpoint Touch Clear and the 200 will disappear Type a temperature that is less than the operating setpoint of the boiler and touch Ok Note System verification paragraph 2 2 9 will need to be made to accept the changes Bryan Steam High Limits DHW high limit Disabled DHW high limit setpoint 200 F Outl Turn off Clear os Audible alarm Lockout Figure 46 Lockout 79 Outlet high limit The indication of Fault is proof that the high limit sensor is functioning correctly as you have reset the high limit setpoint below the operating Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 33 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date
14. Leg A drip leg or sediment trap must be installed in the gas supply line See Fig 1 5A The gas line must be connected to a supply main at least as large as the gas train connection at the boiler This connection should be made with a union so that the boiler gas train components and burner may be easily removed for service 1 4 8 Gas Piping Leak Test Leaks shall be checked using a soap and water solution After completion of the gas piping hookup the Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 3 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 installation must be checked for leaks All joints up to the main motorized gas valve shall be checked A pressure gauge shall be installed down stream of the main motorized gas valve and up stream of the manual gas shutoff valve in the closed position to ensure the main motorized valves are not leaking by During commissioning the remainder of the gas train joints down stream of the main motorized gas valve shall be tested for leaks jurisdictions is acceptable provided that the common vent is sufficiently sized for the capacity of the combined vents 1 5 Requirements 1 5 1 Electrical Requirements 1 4 9 Venting Of Gas Train Components INSTALL GROUND JO
15. Setz Firing rate control OK Cancel Delete Clear Figure 30 Firing Rate Control Page The firing rate control page enables the user to change how the firing rate is controlled The first option is for automatic control based on the current set point The second option enables the user to manually control the firing rate while the boiler is firing The third option can be selected to change the rpm of the blower while the burner is off or in standby The manual firing rate can be changed by pressing the clear button and entering the new value or by using the up and down arrows To accept the new value press the ok button and the boiler will change the firing rate to the new value An error message will display if the value entered exceeds the maximum firing rate or falls below the minimum firing rate Note The firing rate control should come from the factory set to Manual in Run with the manual firing rate value set to the light off rom Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 27 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 2 15 System Date amp Time el Setup gt Display Setup gt Set Date Time 6 27 2012 9 24 AM General com 1 E Set Date Time r er 6 27 2012 EIS 9 23AM 4 gt
16. adjustable must be electrically interlocked with the boiler to prevent boiler operation if the dampers are closed Combustion air openings must never be blocked or obstructed in any manner The boiler room must be at a positive or neutral pressure relative to the outdoors A negative in the boiler room will result in downdraft problems and incomplete combustion due to the lack of alr warnine Failure to provide an adequate air supply will result in boiler damage and hazardous conditions in the building fire and asphyxiation hazard as well as equipment damage Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 6 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 1 6 1 Combustion Air Openings The design of combustion air openings MUST comply with local and or State codes or the authority having jurisdiction As a minimum combustion air openings to the boiler room shall be provided as follows Note Combustion air provided solely from an indoor source is discouraged No dimension for a round or rectangular opening shall be less than 3 1 6 1 1 Two Permanent Opening Method One opening starting within 12 of the top of the boiler room and one starting within 12 of the bottom of the boiler room shall be pro
17. amp 300 Form 2396 Date 2 27 2015 and insert the analyzer probe in the opening Record the O level The offset is a positive value relating to the difference between the Oz level in the stack and the Oz level in the opening in the air exchanger access cover If the offset is LESS THAN 3 then place the sampling probe of the flue gas analyzer in the stack and adjust the Os levels with this offset added to the standard range of O s Use the example below as a guide Example If the Oz level in the stack is 6 and the Oz level in the opening in the air exchanger access cover is 5 then the offset is 1 The range of O2 s for the boiler 6 to 10 will now become 7 to 11 The offset should NOT be greater than 3 If it is higher the air to air exchanger must be replaced Please consult the factory 3 4 Suggested Maintenance Schedule Daily 1 Make visual inspection of monitors and indicators and readings in boiler log 2 Make visual check of instrument and equipment settings against factory recommended specifications 3 Check operation of probe type low water cutoff s to ensure control is functioning gauges record Weekly 1 Confirm boiler area is free of combustible materials and that there is nothing obstructing air openings draft hood relief openings etc 2 Check combustion safety controls for flame failure and flame signal strength as specified in manufacturer s instructions locate
18. and unavailable to change Method Error threshold temperature OFiring rate threshold ODiabled Detection time 20 min 60 min This parameter defines the time before a stage is dropped When the water temperature is above the setpoint by the amount set by the error threshold parameter and all the boilers are at or below the minimum firing rate plus the rate offset the drop stage timer will start When the time is equal or greater than the detection time another boiler will be dropped Error threshold AE Set this parameter to the number of degrees above the setpoint to start the detection timer This setting should be set less than the CH off hysteresis Rate offset 10 This is the percent offset from the minimum firing rate to start the detection timer 100 0 see detection time for further explanation Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 55 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Parameter Value Notes Interstage delay 5 min This is the minimum amount of time to wait before disabling another boiler This parameter may be bidden and unavailable to change Boiler off options CAII boilers off Leave these values as is There is ClDrop lead boiler on e
19. cross sectional area be less that 10 in 6500mm Combustion Air For combustion air where the air supply is provided by natural airflow from outdoors in addition to the opening for ventilation air there shall be permanent opening having a total cross sectional free area of not less than 1 in for each 30 000 BTU hr 70 mm for each kW of the total rated input of the boiler s The location of the opening s shall not interfere with the openings for ventilation air Please refer to CAN CSA B149 1 05 Para 8 4 4 for combustion air openings if there are natural draft fan assisted or power draft assisted equipment in the space When an air supply duct is used to supply combustion air it s discharge opening shall be located where there is no possibility of cold air affecting steam or water lines or other temperature sensitive equipment 1 7 2 2 Combustion Air Supply Dampers Louvers and Grilles The free area of the combustion air supply opening shall be calculated by subtracting the blockage area of all fixed louvers grilles or screens from the gross area of the opening Openings in a fixed louver grille or screen shall have no dimension smaller than 6 mm No manually operated damper or manually operated adjustable louvers are permitted Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 9 Installation a
20. dE AEN 25 Figure 23 Status Page LOCKOUT eessen teen ed ei in aA aaa aat Aa ere eee 25 Figure 24 History Dialoge tia aaa ena aa en a e i ened 25 Figure 25 Lockout History age ia eee RENE aaa on 25 Figure 26 Lockout Detal a e daa ene ae en aac A ats 26 Figure 27 Operation Raeren tee eae ani aa aa an aA egene 26 Figure 28 Annunciation Paga sieaa a tenia a en aaa ene ads 26 Figure 29 Modulation Configuration 0 ccccccscceeceececeeeeaeceeeeeceeeeceaeeesaaeseeeeesaeeesaaeeseaeeseeeeeseaeeesuaeeseneeseaes 27 Figure 30 Firing Rate Control Page ssssssesisessnssrnssrnssrnssrnsstnsstnsstnnstnnstenstenstenstnnstenstnnntenstnnntnnntnnntnnnenn nnt 27 Figure 31 System Date amp Time 28 Figure 32 Display Disgnostce eoria ine araa a aa SEA RTEKA T aE AAA RAAR AEAN E AA ENAA E ANAE 28 Figure 33 Reset Reboot Display 0 ccceeeeeeeeeeeeneeeeeeeneeeeeeaeeeeeeaeeeeeseaeeeeesaeeeeeeaeeeeeseaeeeeeeeneaeeeeeneaeess 28 Figure 34 Outdoor Reset Sensor Confiouraiion nnt 29 Figure 35 ele ele 29 Figure 36 Outdoor Reset Curve cccccccccccceeceeneeceeeeeceaeeecaaeeeeneeeeaeeecaaesseaaeseeeeesaeeeseaesseaeeseeeeeseaeessaaeeneaeeeeaes 30 Figure 37 Central Heat Configuration Modulation Page 31 Figure 38 Central Heat Configuration Central Heat Page 31 Figure 39 Central Heat Configuration Setpoint Page ccccccceceeeceeseeceeeeeceeeeeeaeeeeaeeseeeeeseaeessaaeeseneeseaes 31 Figure 40 Pump Configuration Page 32 Figure 41 Pump output s
21. disconnects to the burner boiler and any other equipment or systems electrically interlocked with the burner or boiler All cover plates enclosures and guards must be in place at all times except during maintenance and servicing 2 1 Boiler Assembly The Triple Flex boiler is a fully integrated assembly consisting of a Metal Fiber Pre Mix Burner Head and the necessary fittings valves and safety devices The boiler equipment list provided in the boiler manual lists the components supplied for the boiler assembly Refer to the boiler dimensional for location dimensions A description of the major components follows For additional information refer to the manufactures literature provided in the boiler manual 2 1 1 Triple Flex Front View Figure 3 Triple Flex Front View 1 The boiler cabinet door provides easy access to boiler and burner components This door should remain closed during normal operation to ensure proper flow of air around the boiler flue collector 2 The boiler supply water connection provides heated water to the system This connection is a standard ANSI 150 class 3 flange 3 The boiler water pressure gauge is 2 diameter and will have a range not less than 1 1 2 nor more than 3 1 2 times the pressure setting of the boiler safety relief valve Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail
22. inquiry bryansteam com 14 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 4 The boiler water temperature gauge is 2 diameter and is located so that it will indicate the boiler water temperature at the supply water connection of the boiler The boiler touch panel display provides a human interface for controlling the boiler Controlling the boiler with the touch panel display will be explained in section 2 2 The boiler on off switch will turn on or off the 120 volt ac control voltage for every electrically connected device This includes the touch panel display There is a soft switch paragraph 2 2 11 provided with the SOLA hydronic control that will put the boiler into standby for an indefinite period of time 2 1 2 Triple Flex Rear View warnine The boiler on off switch will not turn off the 3 phase high voltage power to the motor 7 The boiler lockout reset button is a push button used to reset the hydronic control after a boiler failure The power on light will be white in color and indicates that there is 120 volts ac being supplied to electrically connected devices The enabled light will be green in color and indicates that the boiler is enabled Enabled is a state in which the boiler is allowed to operate within the boilers predefined parameters The fuel on light will be amber in color and indic
23. is inactive and an alert is issued Outdoor boost step 0 234 F Each time the boost time interval elapses and CH demand is not satisfied the effective CH setpoint is increased by the amount specified in CH ODR boost step Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 53 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Parameter Value Notes Outdoor boost maximum off point Enable 32 250 F OShutdown after demand ends OShutdown immediately Disabled Maximum effective CH setpoint Warm weather shutdown will shut down the boilers and system pump when the outdoor temperature equals or exceeds the setpoint Enable warm weather shutdown when the remote STAT is jumped and not controlled by the building Management system The system will shut down after the CH setpoint the off hysteresis has been reached when the Shutdown after demand ends option is selected Setpoint Lead selection method 50 F OSequence order Measured run time Lag selection method OSequence order Measured run time Base load common Method Lead rotation time 7 days 7 days is recommended to reduce cycling Forced lead rotation time 7 days If used set this value the same as the 40 Erro
24. terms of it s listing and the vent manufacturers certified installation manual e A flue gas vent or a vent connector shall not be installed in either a duct or a shaft used for return air hot air ventilating air or combustion air e An appliance that operates at a positive vent pressure shall not be connected to a venting system serving any other appliance The Triple Flex boiler operates at a positive vent pressure e A factory built chimney used for venting an appliance shall be certified 1 7 3 Vent Sizing e A vent or chimney serving a single appliance shall provide effecting venting and shall be sized so that it s effective area is not less than that of the flue outlet diameter of the boiler and in accordance with engineering venting tables acceptable to the authority having jurisdiction e A vent or chimney serving more than one appliance shall provide effective venting and shall be sized in accordance with good engineering practice such as by the use of engineering venting tables acceptable to the authority having jurisdiction 1 7 4 Marking Of Gas Vents Where solid and liquid fuels are used gas vents must be plainly and permanently identified by a label The label should read This gas vent is for appliances that burn gas only Do not connect to incinerators or solid or liquid fuel burning appliances This label must be attached to the wall or ceiling at a point near where the gas vent connec
25. the user Figure 20 Press the Yes button to confirm each safety parameter block If the user selects the No button the safety parameter block remains unconfirmed and the configuration menu page is displayed The boiler remains in an un configured state in this case A B St H gl Safe Berg Verification D Verification ID 10 Connectors S1 38 4 connector type UNCONFIGURED S2 38 6 connector type 4 20mA 3S4 38 8 10 connector type 10K NTC dual safety S5 38 11 connector type UNCONFIGURED S657 39 1 3 connector type UNCONFIGURED S8S9 39 4 6 connector type 10K NTC dual safety Yes No Are these parameters set to proper values Confirm in 28 seconds Cancel Figure 20 Safety Parameter User Confirmation After all safety parameter blocks have been confirmed the user is asked to press and hold the reset button Figure 3 item 7 on the boiler to complete the safety configuration session Figure 21 EISE Bryan Steam Safety Parameter Verification Verification ID Ot PRESS RESET BUTTON AT DEVICE NOW Reset at device is needed Reset must be completed in 27 seconds Figure 21 Safety Parameter Reset When the Reset button is pressed and held for 3 seconds the confirmed safety parameters are committed in the boiler The above reset dialog box automatically closes when this step is completed Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 7
26. vent manufacturers requirements Clearances to combustible materials and supporting requirements per the vent manufacturers installation instructions must be maintained Horizontal sections of the flue vent system must be pitched back towards the Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 8 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 boiler at inch per foot to avoid condensate pooling and allow for proper drainage Venting may be horizontal through the wall installation or vertical through the roof installation The vent system including terminus must be sized in accordance with the flue gas flow s and pressure drop s per Table 4 Note NFPA 54 2009 ANSI Z2223 1 2009 paragraph 12 7 3 3 states The sizing of gas vents for Category Il Category Ill and Category IV Appliances shall be in accordance with the appliance manufacturers instructions warnine Do not use a barometric damper with this boiler This is a positive pressure system The use of a barometric damper may cause flue gases to leak into the boiler room The boiler vent must not be connected to any portion of another vent system without consulting the vent manufacturer The boiler shall not be connected to any part of a vent system servin
27. venting system must be thoroughly inspected internally as well and cleaned as necessary warnine If soot or condensation is apparent a boiler service technician should be consulted The presence of soot indicates poor combustion and possibly hazardous boiler operation Failure to do so may result in fire explosion potential or asphyxiation A combustion test and burner adjustments should be undertaken at once 3 3 Primary Air to Air Exchanger The purpose for testing the primary air to air exchanger is to determine if primary combustion air is circumventing the heat transfer surfaces of the exchanger and diluting the exiting flue gas To accomplish this a flue gas analyzer is necessary and the burner should be locked at any specific firing rate It will be necessary to remove the jacket doors Figure 5 item 2 at the rear of the boiler to expose the primary air to air exchanger access cover Figure 10 Item 4 In the lower right hand corner of the access cover there is a coupling that is plugged Before removing the plug place the sampling probe of the flue gas analyzer in the stack outlet of the boiler and record the Os level in the products of combustion Next remove the plug Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 45 Installation and Operation Service Manual Triple Flex 150 200 250
28. 0 F Off hysteresis 20F On hysteresis 15 F 4 mA water temperature UNCONFIGURED 20 mA water temperature UNCONFIGURED Figure 39 Central Heat Configuration Setpoint Page Setpoint source Local S2 J8 6 4 20mA Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Setpoint Setpoint for normal Central Heat modulation 50 F to 190 F Setpoint when Time Of Day switch is on 50 F to 190 F Time of day setpoint Differential above setpoint when boiler is turned off 2 F to 5 F Off hysteresis Differential from setpoint when boiler is turned on 2 F to 30 F On hysteresis 4 mA water temperature 50 F to 190 F 20 mA water temperature 50 F to 190 F 2 2 23 Pump Configuration AE gt CONFIGURE gt Pump Configuration r B Ste Pum GE al Central Heat pump P Pump control Auto Pump output NONE Pump start delay 0 sec Overrun time 1 min O Use for local demands D Use for Lead Lag Master demands D Use for delayed overrun Advanced The pump configuration page allows the user to setup parameters related to the Pump A
29. 0 MBHy EE 9 1 7 2 2 Combustion Air Supply Dampers Louvers and Gilles ENEE 9 1 7 2 3 Mechanical Combustion Air Supply ENEE ENEE 10 1 7 2 4 Appliance Venting per CAN ZCSA BIAO IO 10 WE AE 10 1 7 4 Marking Of Gas Vents ege edel 10 1 7 5 Solid Fuel Appliance Vents ENEE 10 1 8 Before Placing Boiler In Operation ceeesseesesseessesssecseeseeseesseestesseeseeseessecneesseeseeeseeateeneeseesteeseentesneesneeatenseens 11 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 1 8 1 Cleaning The Boiler And System New Systems ENEE 11 1 8 2 Pre Boil Out Flushing Of System EEN 11 1 8 3 Boll QUt Pro CO QUre ssc eis 11 1 8 4 Replacement Boiler Installations Protection Against Corrosion And Sediment 11 1 9 Draining and refilling the boiler amp system ENEE 12 1 9 1 Filling The System ssesacc dict Adan EE 12 1 9 2 Hydrostatic Test Of Boilers And System ENEE 12 1 10 Boiler Water Lreabtgnt Zeesoges dsestngeedth dese a a a 12 1 10 1 Purpose of Water treatment o0 eesessessseessecstesseeseeseestecseesseesteeseenteeneesseesteeaeentesneeseeatesieenteaneesteeatenteeneeanees 12 1 10 2 Object ves ee AA SEENEN 13 1 10 3 Water SOLER EE 13 1 10 4 Continuous monitoring required nee 13 Section 2 Start Up and Operation ssssssssscsc
30. 2 1 8 Triple Flex Right Flue Collector View Figure 11 Triple Flex Right Flue Collector View 1 High primary air to air exchanger pressure This switch will trip when the air pressure in the primary air to air exchanger rises above the set point indicating that the primary air to air exchanger has become plugged with dust or other foreign matter 2 Condensate trap cleanout This connection is NPT 3 Condensate trap The condensate trap is welded and fixed into place 4 Flue vent temperature sensor 2 2 SOLA Hydronic Control System The Triple Flex is equipped with a Honeywell SOLA control system Figure 3 item 5 This section will explain navigation configuration history and diagnostics 2 2 1 Power up Validation Flip the power button Figure 3 item 6 to the on position After a few seconds of loading the hydronic controls parameters the Home page will appear 2 2 2 Home Page Make sure a screen similar to Figure 12 appears after the system is completely powered up The directional map shown before each page description in this manual will start with this symbol Al Pressing this symbol will return Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 19 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 For
31. 2 2 Pressure IWC 1200 1200 800 800 Min RPM 4600 1600 950 950 Table 12 Approximate Boiler Settings warnine Running the boiler at a higher furnace pressure than listed above could result in PROPERTY LOSS SERIOUS PHYSICAL INJURY or DEATH warninc 2 3 10 Gas Meter Readings Burner input rate can be checked by taking readings from the gas meter Please note checking the rate with a meter is the only way to be sure of input Manifold readings are only an approximate value and may vary from unit to unit Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 In order to obtain accurate data there must be no other appliances using gas from the same meter while the burner input rate is being checked A stopwatch or a watch with a second hand is required to obtain a meter reading Clock the amount of time it takes for the smallest dial to complete one revolution in seconds Use the following formula to obtain the cubic feet per hour throughput of the unit CFH 3600V ER CFH ft hr of gas V ft clocked g time in seconds To obtain the Btu per hour throughput of the unit use the following formula Q CFH h h heating value of fu
32. 200 250 amp 300 Revision 3 Figure 6 Triple Flex Right Side View cccscceceeeeceeeeeeeaeceeseeeeeeeeeeaeeeeaaeedeeeeseaeeesaaeseeaeeseeeeeseaeessaeeseaeeeeaes 16 Figure 7 Triple Flex Behind the Cabinet Door cccccccecceeceeeeeeeceeeeeeaeeeeeeeceaeeesaaeeeeaaeseneeeseaeeesaeeseaeeseaes 17 Figur 8 Air Flow Switch inii ieni inaia iai Mp eel enaa EAR ERENNERT 18 Figure 9 Pilot Spark Igniter Assembly cc ceceeceeceeeeeeeaeeeeneeceaeeeceaeeeeaaeeeeeeeseaeeesaaeseeaeeseeeeeseaeessuaeeseaeeenaes 18 Figure 10 Triple Flex Left Flue Collector View 19 Figure 11 Triple Flex Right Flue Collector View ccccscceesceceeeeeceeeeeeaeceeneeseaeeeseaeeeeaaeseeeeeseeeeseaeeneaeeeeaes 19 Figure 12 Home Page ics teats aici dae eel ee es ied ed at ed N 20 Figure T9 elt DEE 20 Figure 14 Status Page sicuri ENEE ste sted da dete ep elec ae 21 Figure 15 Configuration Menu Page ssssssessessssisssiissirssrrssrissrrssinsstnsstinstinstinstnsstintttantnntt nant nnnnnnntnnnnnn nnt 21 Figure 16 Sample Configuration Page 22 Figure 17 Change Parameter Dialog 23 Figure 18 Safety Parameter 23 Figure 19 Safety Parameter Verification cccccceceeeeeeeeeceeeeeceeeeeceaeeeeaaeceeeeecaeeesaaeeseaeeseeeeeseaeessaeeneaeeeeaes 24 Figure 20 Safety Parameter User Confirmation 24 Figure 21 Safety Parameter Reset riis aieia aa Aaea ia aat a aaa iiaa a Aaa a aiaa aaa Aa Aaa aE AEN aae 24 Figure z2 Home Fage Lockout 22 eet DEENEN
33. 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 52 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Parameter Value Notes Enable OEnabled Disabled Enable this parameter for outdoor reset The parameters for outdoor reset can be found in the Outdoor Reset Configuration page For more information see paragraph 2 2 19 of the IO amp M Maximum outdoor temperature 40 100 F When the outdoor temperature is equal or greater than this value the boiler setpoint will be set to the low water temperature Minimum outdoor temperature 40 100 F When the outdoor temperature is equal or less than this value the boiler setpoint will be set to the Central Heat Setpoint value y1 see paragraph 2 2 22 Low water temperature 50 195 F This value represents the water temperature setpoint when the maximum outdoor temperature is reached Minimum boiler water temperature 50 195 F This value is used to override the low water temperature of the curve created with the above points without changing the slope Outdoor boost time hour min s If CH outdoor reset is not active or if the CH ODR boost time parameter is zero then the boost function is inactive Otherwise the boost time provides a time interval and the other parameters must be valid if they are not the boost function
34. 65 473 3074 E mail inquiry bryansteam com 24 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 NOTE If the user doesn t perform this step the boiler remains in a locked state until the user resolves the unconfirmed safety parameters 2 2 10 Fault Alarm Handling Each boiler reports a fault code when a lockout condition occurs for one of the following annunciations e Burner control e Lockout e Lead Lag control A less serious alarm condition may also occur that is treated as a warning instead of a fault Each boiler can report active fault and warning codes for each annunciation Any new fault code detected in a boiler is indicated as a lockout condition at the display The notification method used depends on the page that is displayed On the Home page the button for the boiler with the fault turns red Figure 22 On the boiler status page the info bar turns red Figure 23 Bryan Steam Figure 22 Home Page Lockout W I Bryan Steam pga Demand Central Heat Firing rate 0 Burner state Lockout Setpoint 1809F Outlet Stack Flame 74 F OPEN 0 00V Setpoints Pumps ON Modulation OFF Central Heat 165 F 180 F 182 F Lockout 67 ILK OFF Low Water Configure Operation Figure 23 Status Page Lockout Diagnostics Details Selecting the info bar will display the history dialog If none of the buttons are s
35. A 1 05 1 41 Full Load Amps N A 6 Service Fuse N A 2 7 Amp Table 2 Electrical Requirements warninc The boiler must be grounded in accordance with the current American National Standard Electrical Code ANSI NFPA 70 Full load Amps include blower and control circuit Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 1 5 2 Sound Pressure Levels Sound pressure levels were measured at 4 1 2 above the floor and 3 from the boiler at the front rear and two sides See Table 3 for decibel readings Decibel Readings Tube Right Model Front Rear Side Side TF150 55 5 58 0 59 5 58 5 TF200 62 1 65 1 66 3 65 4 TF250 77 7 82 8 82 7 82 8 TF300 77 7 82 8 82 7 82 8 Table 3 Sound Pressure Readings 1 5 3 Combustion Air and Flue Gas Flue Gas Comb Air Flow ee gt Req Permissible is GE SCFM AP Thru is 40 XS Venting SA A60 F 200 F TF 150 452 330 ane Max 0 2 WG TF 200 603 441 Max TF 250 753 550 02 WE Max TF 300 904 661 02 WG Max Table 4 Boiler Draft and Combustion Air Requirements 1 5 4 Pump and Piping Requirements Pump piping and sy
36. Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 B BRYAN BOILERS Originators of the Flexible Water Tube design Triple Flex High Efficiency Boilers Installation Operation and Maintenance Manual Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Table of Contents Section 1 Installation Instructions ccssesessseeeeesesneeseseeeesseseeeeseeeseeeneeeseononaneneeseseseneneeeeseaseeneeesnonananeneneeeaees 1 1 1 Boiler Foundationi ivaa Eder ee 2 LE lernen EE E E a S 2 1 2 1 Minimum Clearances to Combustible Surfaces seen 2 1 3 Rec iving The Bole risitsccnc cick deataecin ENEE SEENEN 2 TA Boiler ee EE 3 1 4 T FLOW Connecti oMi aiei a a a ii a a 3 1 4 2 Safety Reliet Valves insorsero innen a i aa AA a an 3 1 4 3 Expansion Tank Gonnectonsin iersinii e ea EE 3 1 44 Drain Connection erreneren 3 1 4 5 Condensate Drain Connecthon ENEE EEN 3 1 4 6 Gas Supply tConnecton ege SEENEN 3 T47 Ke NEE 3 1 4 8 Gas Piping Leak Test geen EEN 3 1 4 9 Venting Of Gas Train Components ENEE 4 Ee stones wee ele dts ce a ah a aad od 4 1 5 1 Electrical Requirements c ccihaiateti Aina Maanteaaiee ated EE 4 25 2 SOUNG Pressure LEVELS si
37. INT UNION HERE INSTALL SHUTOFF VALVE OUTSIDE JACKET GAS MAIN SIZE AS REQUIRED DRIP LEG Figure 2 Main Gas Inlet Connection Normally open vent valves when supplied These valves must be piped to outdoors using pipe no smaller than that of the valve Gas pressure switches All gas pressure switches provided are of the VENTLESS type and do not require venting to atmosphere Gas pilot pressure regulator A vent limiter for the pilot pressure regulator is provided eliminating the need to run a vent line to atmosphere Some jurisdictions may not accept a vent limiter and require the vent to be piped outdoors Main gas pressure regulator actuator This regulator actuator is provided with a vent tapping that must be piped to atmosphere NOTE Do not use Teflon tape for threaded joints in gas piping The use of a common vent in some warnine All electrical connections must conform to the National Electrical Code and to all other applicable State and Local Codes See boiler wiring diagram and equipment list for specific voltage requirements Model TF300 250 TF200 150 200 V 240 V 60 Hz 3 Ph Blower Motor KW HP 3 4 02 N A Poong 15 6 N A Amps Service Fuse 3 20 Amp N A 400 V 480V 60 Hz 3 Ph Blower Motor KW HP 2 5 3 35 N A Full Load 52 N A Amps Service Fuse 3 5 Amp N A 200 V 240 V 60 Hz 1 Ph Blower Motor KW HP N
38. LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com
39. Pump B and Pump C contacts These contacts can be used for stand by loss damper combustion air damper isolation valve pumps etc Ki a E neuen e Pump output gt O Pump A Figure 40 Pump Configuration Page Pump B Pun R Pump C NONE er demands F j in OK Cancel Advanced Figure 41 Pump output selection Select the pump output parameter and chose Pump AT to use contacts J4 6 and J4 7 or Pump B to use contacts J4 4 and J4 5 or Pump C to use contacts J4 2 and J4 3 Bryan Steam Pump Configuration lt 4 Central Heat pump gt Pump control Auto Pump output NONE Pump start delay 0 sec Overrun time 1 min M Use for local demands EE M Use for Lead Lag Master demands DO Use for delayed overrun Advanced Figure 42 Parameter selection Make sure that Use for local demands and Use for Lead Lag Master demands is checked Select the Advanced option to setup how the contacts that you selected will be turned on or off Bryan Steam Pump Configuration al Central Heat pump P On options Force on Force off Miscellaneous O Local burner demand Central Heat M Demand O Service active DHW O Demand D Service active Local Lead Lag O Demand O Service active Frost Protection O Central Heat O DHW Aux pump O X is set O Y is set O Z i
40. able a boiler feature Selecting a parameter group from the menu displays parameters exclusively applicable for the functional group on the page Figure 16 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 21 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Bryan Steam H Central Heat Configuration D D ai Central Heat P CH enable Enabled Demand switch Modulation sensor only CH has priority over Lead Lag No Figure 16 Sample Configuration Page These parameters can be edited and when the user is finished control returns back to the configuration menu page Each parameter is displayed in its group If there are more parameters than will fit on the screen a vertical scroll bar allows the user to scroll up and down to view all parameters The parameter name is displayed on the left and the current setting is displayed in the text box on the right 2 2 7 Configuration Password Any user can view the configuration parameters default mode No access level password is required to view the parameters A valid configuration password for the parameter s level must be entered before the parameter can be changed The password need only be entered once while the user remains on the configuration pages Leaving the configurat
41. ance to clean the piping because of possible leaks occurring in badly corroded lines Should the customer refuse cleaning it is necessary to install filtration equipment Install either a fibrous filter or a centrifugal filter in the boiler return piping This will collect and remove sediment from the system A booster pump may be required to overcome the additional pressure drop introduced in the line by the filter When filling the system provide chemical treatment as outlined in Section 1 10 Failure to properly clean the system or to install mechanical sediment removal equipment can result in tube blockage and severe corrosion plus damage to pumps controls and air removal devices Inspect repair as necessary or replace system air control devices Install gauge glasses on air expansion tanks and install a tank fitting in the system connection to the tank Install a strainer in the boiler return piping 1 9 2 Hydrostatic Test Of Boilers And System After completing the boiler and burner installation the boiler connections fittings attachments and adjacent piping must be inspected for leaks by filling the unit with water The pressure should be gradually increased to a pressure just below the setting of boiler safety relief valve s Remove the boiler tube access panels see dimensional drawing in the boiler manual Inspect the tube to header joints to be certain that all tube fittings are sealed This is necessar
42. ases or decreases as the load increases or decreases in the hydronic system The regulating gas valve is a 1 1 differential pressure air gas ratio controller This means that the control adjusts the same pressure difference on the gas side as it senses on the airside The airside pressure is the difference between the pressure in the burner housing and the pressure downstream of the furnace section The gas side pressure is the difference between the pressure upstream and downstream of the gas limiting orifice valve For the locations of the gas and air connections see Figure 47 Air to gas ratios are adjusted with the gas limiting orifice valve Figure 7 item 26 During the burner pre purge period when the gas valve is closed only the air pressure Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 34 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 difference acts on the regulator causing the air diaphragm to move to the left and closes the regulating hydraulic bypass valve When the actuator is powered the gas valve begins to open The downstream gas pressure difference immediately begins to increase until the gas pressure difference is in balance with the air pressure difference 2 3 2 Test Setup Connect a u tube manometer to the gas mani
43. ates that the boiler producing heated water is firing and The boiler lockout light will be red in color and indicates that the boiler has failed The SOLA control will have additional information displayed on the touch panel display These failures will be explained in section 2 4 FE igure 4 Triple Flex Rear View The flue gas vent is 8 diameter and exhausts products of combustion Refer to section 1 7 for installation details The rear jacket access panel provides access to the combustion air blower for servicing The boiler return water connection receives cooled water from the system This connection is a standard ANSI 150 class 3 flange The drain connection is 1 NPT and provides a means for draining water from the boiler For installation details refer to paragraph 1 4 4 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 1 3 Triple Flex Left Side View li o e i 1 3 4 S l i P ee DN EH IEN NIE aaja NIE EI IEN wo Figure 5 Triple Flex Left Side View 1 2 This jacket access panel will permit access to t
44. ation cesseessesesssessesssecstessesseeeseesecseesseesseeseeateeseesseessesseenseaseeseeaeeeseentesneesneeaeenseens 31 2 2 23 Pump Configuration EENEG EENEG 32 2 2 24 Performing High Limit Test ee 33 2 2 25 Modbus Communication 34 2 3 Boiler Gommissionin neninn na a a E ENER 34 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 leie Oe 34 23 2 Test SQtup EE 35 2 3 3 Pre Checks And Setup eigtl 35 2 3 4 Operating Data Label iaieiiea aeeie e aeaaaee aaa aaaeeeaa ae aata 35 2 3 5 Dre Rum ied ieisiekide bene a aE a a a A a N 36 23 6 Pilot A0 Steeg 36 2 337 Initial BR E 36 2 3 8 Adjusting Boiler Maximum Input ENEE 37 2 3 9 Adjusting Boiler Minimum Input ENEE 37 2 3 10 Gas Meter Readings zeguer 37 24 TroubleShOOtin geeiert Besteet eben teh asthe te nba wick andre e tee Gebake 39 2 4 1 Burner Internal Thermal Fuse eet inaa Nai 39 2 4 2 Lockout and Hold Codes EEN 40 24 3 Alert CodeS iaa edel AER 43 Section 3 Care and Maintenance eer 44 3 1 Draining The Syst Msininiin aa a a aa a Mie doce eda nde 45 3 2 External Fire Side Clearing cesseessesssecssesseesseeseesessessseeseeeseessecneesseesseseeaseeseesseeseeeseeatesneeseeatesseeneesneeaneeatenseens 45 3 3 Primary Air to Air Exchanger estate elei 45
45. ave the same access level If this condition isn t so the user is asked to enter another password when a higher access level is needed Select Begin button to start the verification process Each safety parameter group is verified one at a time until all have been verified Figure 19 A verification step is required for each safety parameter block that is changed The verification steps do not have to be completed immediately the user can traverse between parameter groups before the verifications are done If the user is logged in with the appropriate password and has changed a safety configuration parameter a verify button is enabled that allows the user to conduct verification sessions If the user terminates the safety configuration session after it has started the boiler is left in an un configured boiler will not operate state The user can terminate the session by pressing the Menu button or by attempting to leave the Verification page with the Home or Back buttons top left and right screen corners respectively The user is warned that leaving the session at this point leaves the boiler in an un configured state and confirms whether the user still wants to do so The settings of all parameters in each safety block must be confirmed to commit them to the boiler Selecting the begin button will start the verification process The settings for all safety parameters in each changed block are presented and confirmed by
46. ay that the Burner switch Lead outlet sensor OSlave outlet sensor average ODisabled controls a stand alone SOLA If On then the LL master is enabled to operate If this parameter is Off then the LL master turns off all slaves and enters an idle condition This parameter is installation dependent Off hysteresis SF The boiler will cycle off when the header temperature reaches this amount above the CH setpoint value For example with the current settings the boiler will cycle off at 185 F On hysteresis The boiler will cycle on when the header temperature reaches this amount below the CH setpoint value For example with the current settings the boiler will cycle on at 165 F Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 49 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Parameter Value Notes Hysteresis step time 0 sec Leave this setting set at 0 This will keep this pointless feature disabled P gain 50 The value of the proportional term of the PID equation Increase this value to decrease the amount of time it takes to reach setpoint Decrease this value if the water temperature over shoots the setpoint and the boiler cycles off before the burner reaches minimum fir
47. cal treatment for the first filling plus additional periodic chemical treatment depending on system water losses and the makeup requirements All water introduced into the boiler should be softened and should include an oxygen scavenger like sodium sulfite This is required to remove dissolved oxygen from the water Dissolved oxygen will cause severe system corrosion Dissolved Oxygen lt 0 007 ppm Total Iron lt 0 1 ppm Total Copper lt 0 05 Total Hardness as SE ppm grains gal pH 8 3 10 0 Nonvolatile TOC lt 1 ppm Oily Matter lt 1 ppm Table 8 Recommended Feed Water Limits Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 13 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Section 2 Start Up and Operation warnine Improper servicing and start up of this equipment may create a potential hazard to equipment operators or persons in the building Only fully trained and qualified personnel should do servicing and start up warnine Before disconnecting or opening any fuel line cleaning or replacing parts of any kind take the following precautions Turn OFF the main fuel shutoff valves including the pilot gas cock if applicable Turn OFF all of the electrical
48. ch was turned ON 44 Low voltage was detected in safety processor 45 High line frequency occurred 46 Low line frequency occurred 54 Safety processor brown out reset occurred 56 Application processor brown out reset occurred 115 Fan was limited to its minimum duty cycle 460 LCI demand lost in run 461 Demand lost in run 462 STAT demand lost in run 463 Demand lost in run due to no flame Note This is an abbreviated list of alert codes For a full list of alert codes refer to the Honeywell R7910A manual Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 43 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Section 3 Care and Maintenance Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 44 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 warnine The boiler area should be kept free of combustible materials gasoline and other flammable liquids The boiler and venting system must be kept free of obstructions of the air louvers The following procedures must be conducted as outlined to prevent damage to and assure safe operation of the boiler
49. csssssssssesssssssssessseeeeeeeesesesesseseeeeneenscesesesesenananeaeseeeseeeeneeeeseseeees 14 2 1 Boiler Assembly 20 14 2 11 Triple Flex Front View astelle a ee Gebei 14 2 1 2 Triple Flex Rear View ee 15 RER MIER ECHT EA UE 16 2 14 Triple Flex Right Side Miguel ANA en eons ar ad ee 16 2 1 5 Triple Flex Behind the Cabinet Door ENEE 17 2 1 6 Pilot Spark leniter Assembly edit eerste anaa 18 2 1 7 Triple Flex Left Flue Collector View ENEE 19 2 1 8 Triple Flex Right Flue Collector View ENEE 19 2 2 SOLA Hydronic Control System sssini EEEEEN 19 2 2 k Power up Validation tee EE eene EEN 19 Ze Died Elei 19 2 2 9 PAGE NAVIGATION E 20 22 4 Key bOard NEE 20 2 2 5 Status Page eet 21 2 2 6 Configuration Pagen eke ee e ereescht Abee adenine 21 2 2 7 Configuration Password sini deine a a aiaa ai aaa aa Naaah 22 2 2 8 Change Parameter Settngs ENEE 23 RE EN le ale EE 24 2210 Fault Alarm Handling tegen ee 25 2 2 1 OUT e He lte at RE He 2 2 13 Modulation Configuration cesseessseseesseessecsecstesseeseeeseesecseesseesseeseeateeneesneeseesseenseaseeseestesseentesneeseeeaeenseens 27 2 2 14 Firing Rate Control Page ee EES 27 2 2 15 System Date amp Time aens a aade e aae KEEA AA E Aaaa Danaa EE ane Kaana 28 22 16 Cah brate TOUCH Screen eege estate 28 2 217 Reset Reboot RUE EE 28 22 18 RENAME Lg E 28 RER ele ell E 29 2 2 20 Remote Setpoint 4 2Z0m4Al eet 30 2 2 21 Remote Modulation 4 Z0mAl eessen 30 2 2 22 Central Heat Confeur
50. d additional air shall be provided to replace the exhausted air Each boiler and other appliance must be interlocked to prevent operation when the mechanical air supply system is not in operation If the combustion air is provided by a buildings mechanical ventilation system the system shall be sized to provide the specified combustion air in addition to the ventilation air requirements 1 6 2 Louvers Grilles and Screens 1 6 2 1 Louvers and Grilles The required size of openings for combustion ventilation and dilution air shall e based on the net free area of each opening Where the free area through a design of louver grille or screen is know it shall be used in calculating the size opening required to provide the free area specified Where the louver and grille design and free area are not know it shall be assumed that wood louvers have a 25 percent free area and met louvers and grilles have 75 percent free area Non motorized louvers and grilles shall be fixed in the open position 1 6 2 2 Screens Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 7 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Minimum Screen Mesh Size Screens shall not be smaller than 1 4 mesh 1 6 2 3 Motorized Louvers Motorized louve
51. d at the back of this manual 3 Check all limit controls 4 Check low water cutoff as described above Revision 3 Monthly 1 Check high and low gas pressure interlocks Refer to manufacturer s instructions for correct procedure Annually 1 The flue gas passages and the exterior surfaces of the boiler tubes should be inspected at least annually Any accumulation of soot or debris should be thoroughly cleaned out 2 If the yearly inspection of the boiler tube surfaces reveals a build up of soot carbon the tubes surfaces should be thoroughly brushed Failure to do so may result in fire or asphyxiation hazards 3 The boiler pressure vessel and piping should be checked annually 4 Check combustion and setup per section 2 3 5 Check primary air to air exchanger per section 3 3 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 46 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Section 4 Lead Lag Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 47 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 4 1 Lead Lag Parameters The Sola control furnished o
52. ded by the hydronic control Make sure blower is not running in standby 4 Airflow switch is stuck closed 78 Demand Lost in Run 1 Check wiring and correct any possible errors 2 H previous steps are correct and fault persists module replace the 79 Outlet high limit 1 Check wiring and correct any possible errors 2 Replace the Outlet high limit 3 If previous steps are correct and fault persists module replace the H ort 80 DHW high limit 1 Check wiring and correct any possible errors 2 Replace the DHW high limit 3 If previous steps are correct and fault persists module replace the H ort 91 Inlet sensor fault 1 Check wiring and correct any possible errors 2 Replace the Inlet sensor 3 If previous steps are correct and fault persists module replace the 92 Outlet sensor fault 1 Check wiring and correct any possible errors 2 Replace the Outlet sensor 3 If previous steps are correct and fault persists module replace the 93 DHW sensor fault 1 Check wiring and correct any possible errors 2 Replace the DHW sensor 3 If previous steps are correct and fault persists module replace the 94 Header sensor fault 1 Check wiring and correct any possible errors 2 Replace the header sensor 3 If previous steps are correct and fault persists module replace the 95 Stack sensor fault 1 Check w
53. e After circulating water for two to three hours the system should be drained completely and refilled with fresh softened water see section 1 10 Usually enough of the cleaning solution will adhere to the piping to result in an alkaline solution satisfactory for operation A pH reading between and 8 5 10 5 is preferred If necessary to increase the pH a small amount of cleaner may be added 1 8 4 Replacement Boiler Installations Protection Against Corrosion And Sediment Clean or replace all system piping and heating Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 units Arrange for chemical or mechanical cleaning of the entire system A chemical treatment company should be consulted for the proper means of any chemical cleaning Replace any piping that is deteriorated beyond safe or cleanable condition Flush the system clean being certain to isolate the boiler 1 9 1 Filling The System warnine DO NOT FLUSH THE SYSTEM THROUGH THE BOILER warnine Use only clean softened and treated water Chemical treatment of the raw water is essential when filling or refilling the system see section 1 10 For some old systems there is a reluct
54. e an outdoor sensor connected to terminals J8 11 and J8 12 of each boiler with outdoor reset enabled ALI Bryan Steam Outdoor Reset Configuration Central Heat Enable Enabled A Maximum outdoor temperature 60 F Minimum outdoor temperature O F Low water temperature 1000F Minimum boiler water temperature 1109F Outdoor boost time 0 sec Outdoor boost step Ke Figure 35 Outdoor Reset KE Show Line Maximum outdoor temperature x2 When the outdoor temperature is equal or greater than this value the boiler setpoint will be set to the low water temperature S5 J8 11 sensor 10K NTC single non safety Outdoor source temperature S5 J8 11 sensor When multiple boilers are connected together and the built in Lead Lag is used only one boiler that is not the boiler hosting the lead lag has to have an outdoor sensor Note System verification paragraph 2 2 9 will need to be made to accept the changes made to the sensor configurations Minimum outdoor temperature x When the outdoor temperature is equal or less than this value the boiler setpoint will be set to the Central Heat Setpoint value y1 see paragraph Error Reference source not found Low water temperature K This value represents the water temperature setpoint when the maximum outdoor temperature is reached Minimum boiler water temperat
55. e viewed the same way non safety parameters can be viewed If the user makes no attempt to change a safety parameter the user isn t required to enter safety verification mode Safety parameters are grouped into blocks that include only safety parameters not a mixture of safety data and non safety data All parameters within the safety group undergo a verification process see paragraph 2 2 9 A safety parameter group is identified on the display to indicate when the configuration parameters are safety related Figure 18 is a warning to only proceed if qualified to change safety parameters Note If not qualified then touch OK and proceed no farther until a qualified person is onsite to make changes to the safety parameters B Safety Parameter Figure 18 Safety Parameter Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 23 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 2 9 Safety Verification el os CONFIGURE gt VERIFY B St H gl Safe Pae meter Verification Verification ID Select Begin to start verification Begin Figure 19 Safety Parameter Verification For safety configuration parameters safety verification is required to commit the changes All safety configuration parameters in the group should h
56. eased warnine Do not adjust the low fire displacement more than 1 4 to 1 2 turn for each main flame establishing period The boiler will light off at approximately 1 5 times the minimum firing rate rom The boiler will hold in this position for no less than 5 minutes to establish a stable flame before releasing the boiler to full modulation Observe combustion Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 36 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 readings and make small adjustments to the low fire displacement of the pressure regulating actuator Figure 7 item 2 when the O2 is not within 6 to 10 Allow sufficient time for combustion to stabilize after each 4 to 1 2 turn of the low fire displacement Figure 7 item 2 2 3 8 Adjusting Boiler Maximum Input O2 levels below 6 will overheat the metal fiber burner and cause the fuel air mixture to ignite inside the burner An internal thermal fuse is provided to open when the internal burner temperature reaches 425 F After the flame stabilization period increase the firing rate in 500 rpm increments until the maximum modulation rate paragraph 2 2 13 is reached For each 500 rpm increment observe combustion readings and make adjustments to the gas
57. eecaeeeeaeeceeeesaaeeesaaeseeeeeseeeeseaeeseeeseenees 18 Table 11 High and Low Pressure Switch Settings cccccceeeseceeeeeeeeeeeeeeceeeeecaeeesaaeeseeeeseeeeseaeeesaaeseanees 35 Table 12 Approximate Boiler SettinS cccccecsceceeceeeeeeeeeeeeeeeeeceaeeeceaeeeeaeeseaeeeseaeeesaaesseaeeseaeeessaeeeseesennees 37 Table 13 Gas Pressure Correction 0 ccccccceeeeeneeeeeeeecaeeeeaeeceeeeeceaeeecaaeseeaeeseaeeeseaeeesaaeeseneeseeeesaeeseaeeennees 38 Table 14 Gas Temperature Correction 0 ccccceccceceeececeneeeeeeeeeeeeecaeeecaaeeseaeeceaeeecaaeeesaaessaeeeseaeessaeeseeesennees 38 Table 15 R7910A Lockout and Hold Codes cccccccececeeeeeeeeeeeeeceeeeeeeaeeeeneeseneeesaaeeesaaeseeneeseeeesaeeeseeeeenees 40 Tables16 Alert ee EE 43 Table 17 Lead Lag Parameters Worksheet AA 49 Figures Figure 1 Minimum Clearances ssssseessssenssersstrsstrsstrsstttstesstensttnsttntttntttnnt tnnt tnttnnnttnntnntnnnnnnnnen nennst nenn 2 Figure 2 Main Gas Inlet Connection ccceceeeceeceeceneeeeaeceeneeceeeeeceaeeeeaaeeeceeeseaeeesaaeeesaaeseeceeseaeeesaeeeeeeseenees 4 WRillCERgdelC HK As rell 14 Figure 4 Triple Flex Rear EE 15 Figure 5 Triple Flex Left Side View 16 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com iv Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150
58. el in Btu ft If the meter is not calibrated for gas temperature and pressure correction factors must be applied to determine correct rate in SCFH standard cubic feet per hour Consult the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the local gas utility for further information Refer to Table 13 for correction factors for the gas pressure at the meter Refer to Table 14 for gas temperature correction factors Gas Pressure at Meter Corr Factor 14 w c 1 034 21 w c 1 051 1 psig 1 061 2 psig 1 136 5 psig 1 340 Table 13 Gas Pressure Correction Gas Temp at Meter Corr Factor 40 F 1 04 50 F 1 02 60 F 1 0 70 F 981 80 F 963 90 F 945 Table 14 Gas Temperature Correction To correct for pressure and temperature use the following formula Q ES Qt t t pressurecorrection table 2 2A t temperature correction table 2 2B Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 38 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 4 Troubleshooting 2 4 1 Burner Internal Thermal Fuse wanne The burner must NOT be operated if the fuse faulted DO NOT by pass the fuse by jumpering the leads of the fuse together A burner temperature fu
59. elected the dialog box closes after 30 seconds Demand Central Heat Firing rate 0 RPM Burner state Lockout Fan speed 0 RPM 4 Setpoint 1809F C Lockout 67 ILK OFF Low Water D B 1 Se Modulation f Central Heat d Lockout alert ence Configure Details Lies Figure 24 History Dialog Lockout history can be displayed for the last 15 lockouts or alerts by selecting respective button AA Bryan Steam kel gl Lockout Histo D Time Cycle Description 06 25 12 02 56 38 PM 40 67 ILK OFF eg 06 25 12 02 42 41 PM 39 2 Waiting for safety data verification 16 2 Waiting for safety data verification 3 109 Ignition failed 3 109 Ignition failed 3 107 Flame lost early in Run 2 105 Flame detected out of sequence gt 3 01 00 PM Clear 6 25 12 east Alerts gt gt Figure 25 Lockout History Page Selecting a lockout from the list will display more information for that lockout as shown in Figure 26 Upper left corner Date and time of lockout Cycle The cycle number the lockout occurred The number of hours the boiler has run since startup Hours State What the boiler was doing at the time of the lockout In this case the boiler was running The boiler could have been in standby pre purge post purge etc Timer The elapsed time from the beginning of this cycle the lockout occurred This can be very helpful for troubleshooting a lost flame in MFEP main flame
60. election 0 eee eee cece eeee ee ee teen cette ance ee te nace eee aeeeeeteaeeeeeseaeeeeeeeaeeeeeseaeeeeeteeeaeeeseeeaeees 32 Figure 42 Parameter selection ccceeseceeeeeeneeeeeeeeeeeeeeeeeeeeeeaeeeseeaeeeeeeeaeeseseeaaeeeseaaeeeseeaeeeeeegenaeseeseneeees 32 Figure 43 ue Mr EL WEE 32 Figure 44 High Limits Me mses is teas ctbcas eea a A di cauiee E s EE A E ee 33 Figure 45 Outlet high limit setpoint 0 cee eeeee eee ee cece eeeeaeeeeeeeceeeeeceaeeecaaeeeeeeecaeeeseaesseaaeseneeeseaeeeseaeeseaeeseaes 33 Figure 46 Lockout 79 Outlet high mp 33 Figure 47 Air Gas Ratio TappingS cccccccesceceeeeceeeeeeaeceeneeceeeeecaaeeeeaaeseeeeesaeeesaaeseeaeeseneeeseaeessiaeeseaeeeeaes 34 Figure 48 Operating Data Label A 36 Figure 49 Multi Boiler Field Wiring A 57 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 5 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Section 1 Installation Instructions Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 1 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Note Please read and save for future reference the entire ins
61. fold pressure tapping Figure 7 item 12 Connect a 0 5 psi gauge in the port provided in the low gas pressure switch connection Figure 7 item 28 Connect a u tube manometer to the pilot gas pressure port provided Figure 7 item 14 A suitable combustion analyzer shall be used for measuring O2 CO and Nox levels The analyzer probe should be inserted in the stack above the boiler outlet and before any draft controls Calibration is required for the Nox and CO cells at the time of commissioning 2 3 3 Pre Checks And Setup Close the manual gas cock Figure 7 item 4 warnine Do not open the manual main gas cock Figure 7 item 4 before all pre checks setups and dry runs have been successfully completed Use a voltmeter to check for the proper incoming main voltage and the proper control voltage from the control circuit transformer Refer to the electrical wiring diagram and boiler rating label for proper voltages Check all high and low pressure switches for proper settings settings Refer to Table 11 for proper High and Low Pressure Switch Settings Setting IWC Description TF150 TF250 300 200 High Gas Press 5 6 Low Gas Press 9 9 Low Pilot Gas Press 3 3 High Burner Air Press 9 9 High Exchanger Air 11 11 Press Table 11 High and Low Pressure Switch Settings Make sure the boiler is full of water and proper flow has been established
62. g Data High Fire Blower RPM s Low Fire Blower RPM s gt High Fire Burner Manifold Gas Pressure Low Fire Burner Manifold Gas Pressure Gas Supply Pressure to Boiler at High Fire Minimum Gas Supply Pressure to Boiler is 14 WC Maximum Gas Supply Pressure to Boiler is 5 PSIG Figure 48 Operating Data Label _ 2 3 5 Dry Run Navigate to the Operation Page Figure 27 Toggle the burner switch to on Navigate to the Status Page paragraph 2 2 5 If there is demand for hot water the burner state will display driving to purge When the fan speed is within 3 of the firing rate for 3 seconds the purge timer will start and count to 30 After 30 seconds the fan speed is reduced to the light off rate When the fan speed is with in 3 of the firing rate for 3 seconds the ignition transformer and the pilot valve are energized The pilot will light and can be observed from the observation port Figure 5 item 4 After a duration of 5 seconds the ignition transformer will de energize The pilot valve will stay energized for another 5 seconds before the main gas valves are energized During this 10 second period the pilot should be adjusted according to paragraph 2 3 6 The main gas valves will energize for 10 seconds After this 10 second duration the pilot valve is de energized The control will lockout with a code of 106 Flame lost in Main Flame Establishing Period
63. g a Category or Category Il appliance nor shall a Category or Category II appliance be connected to the vent system serving this boiler Improper connection of venting systems may result in leakage of flue gases into building spaces Note An existing masonry chimney may be utilized PROVIDING that the existing chimney is lined with Special Gas Vent material s primarily AL29 4C There are venting manufacturers that have these products available 1 7 2 Combustion Air and Venting Requirements for Canada Canadian Standard CAN CSA B149 1 05 Natural gas and propane installation code specifies venting systems and air supply for appliances in Section 8 Paragraph 8 1 4 states Air supply shall be provided in accordance with Clause 8 4 when either an appliance or a combination of appliances has a total input exceeding 400 000 Btuh Air supply is defined as combustion air excess air flue gas dilution air primary air secondary air and ventilation air The air supply requirements below are a summation of Clause 8 4 specific to the Triple Flex boiler 1 7 2 1 Air Supply Requirements per CAN CSA B149 1 05 for Appliances having an input exceeding 400 MBH Ventilation Air an opening for ventilation air at the highest point that opens to the outdoors shall provide Ventilation of the space The cross sectional area of this opening shall be at least 10 of the area required for combustion air but in no case shall the
64. g feet legs MUST BE REMOVED after the boiler is set in place on its concrete foundation before any piping electrical connections are made It is recommended that the plastic protective cover be left on as long as possible to reduce finish damage from the installation 1 4 Boiler Connections Do not run any pipes along the tube access panel side of the boiler Maintain clearances as shown on the dimensional drawing for servicing of the boiler tubes Provide at least 48 from the front of the boiler unless a larger dimension is indicated on the dimensional All piping should be designed and installed to avoid any loadings on the boiler connections or piping 1 4 1 Flow Connection The system supply and return flow connections are shown on Figure 3 and Figure 4 respectively A gate valve should be installed on the boiler outlet and inlet lines This allows the boiler to be isolated from the heating system for draining and servicing 1 4 2 Safety Relief Valves Safety relief valve s are shipped loose Connections are provided in the top of the boiler for the safety relief valve s The safety relief valve discharge piping must be the same size as the safety relief valve discharge opening and run to a point of safe discharge Avoid over tightening as this can distort valve seats All piping from the safety relief valve s must be independently supported with no weight carried by the valve 1 4 3 Expansion Tank Co
65. he primary air to air exchanger This jacket access panel will permit access to the primary air to air exchanger and the boiler convection tube access panels These jacket access panels will permit access to the convection and furnace tube access Flame observation port This port provides visual access to observe the pilot and main flame during operation and service This jacket access panel will permit access to the majority of the boiler devices warnine The flame observation port will become very hot during normal operation Burn injuries can occur if come in contact with the skin 2 1 4 Triple Flex Right Side View EE 3 4 5 EH E fy E3 ET fy EH EH E fy Eq fy ms LI Figure 6 Triple Flex Right Side View Jk 2 Main gas inlet connection This connection is a 2 male national pipe thread Condensate Drain Connection This connection is a 1 male national pipe thread For installation details refer to paragraph 1 4 5 This jacket access panel will permit access to the majority of the boiler devices These jacket access panels will permit access to the flue collector There is no practical reason for the removal of these panels This jacket access panel will permit access to the condensate trap The condensate trap is provided with a NPT plugged connection for cleanout purposes This jacket access panel will per
66. he system Should a different communication protocol be required Bryan Steam LLC can provide a conversion package to numerous other protocols Universal Communication Gateway Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 48 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Table 17 Lead Lag Parameters Worksheet Modulation backup sensor Parameter Value Notes Master Enable Enabled Enable this option on the boiler that ODisabled will host the lead lag only CH setpoint 180 F This is the setpoint for the water temperature in the system header When outdoor reset is enabled this is the default setpoint when the outdoor sensor fails or the boiler that the outdoor sensor is connected is powered down This setpoint also provides one coordinate for the outdoor reset curve CH time of day setpoint 120F This setpoint overrides the CH setpoint when terminals J10 2 amp 3 are made DHW setpoint 50 195 F This Setpoint is used whenever the time of day switch is off or not connected unused DHW time of day setpoint 50 195 F This Setpoint is used when the time lof day switch is on Modbus port OMB1 The Triple Flex boiler will use MB2 OMB2 to host the lead lag ONo port Operation enable ON This controls the LL master in the O OFF Same w
67. ing rate I gain 10 The value of the integral term of the PID equation Raise this value in increments of 1 to correct for load swings Lower this value if burner starts to oscillate up and down D gain Demand switch STAT terminal The value of the derivative term of the PID equation Typically this value does not need to be changed Change this value at your own risk The STAT terminal J8 1 amp 3 is used for a building demand enable call for heat This allows for a system pump to be turned on and remain on until the building no longer demande heat In the absence of a building management system terminals J8 1 amp 3 can be jumped to provide a continuous building demand Use Warm Weather Shutdown with an outdoor sensor to interrupt this demand This demand is independent of burner demand OEnviraCom remote stat Operates the same as the STAT terminal above by using an EnviraCom system STAT OSTAT terminal or EnviraCom This option allows a building demand from either the STAT terminal or an EnviraCom system Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 50 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Parameter Value Notes OModulation sensor This opt
68. io control The actuator controls the pressure difference across the gas limiting orifice valve Figure 7 item 26 as a function of the pressure difference across the furnace section so that remains constant POR OT 10 Flame scanner 12 13 14 15 16 17 Manual main gas shutoff valve Pilot ignition transformer Manual pilot gas shutoff valve Pilot gas pressure regulator This regulator provides a constant gas pressure to the pilot when the solenoid valve is energized The pressure can be adjusted by removing the cap and adjusting the slotted screw clockwise to increase the pressure and counter clockwise to decrease the pressure The pilot gas supply is taken upstream of the main gas cock so the pilot may be lighted and adjusted with the main gas cock closed Low pilot gas pressure switch Manual Reset Pilot spark igniter assembly For further detail see Figure 9 Pilot gas solenoid valve Main gas manifold pressure test port 1 4 NPT Main high gas pressure switch Manual Reset This switch should be set 1 of water column above the maximum gas manifold pressure Pilot gas pressure test port 1 4 NPT This port is also used to record the furnace pressure Table 13 Boiler water flow switch The boiler water flow switch is adjustable within the parameters listed in the table Mode Of Operation Settings Switch Switch Closed Open Minimum 30 gpm 12 gpm Maximum
69. ion generates a demand based on the temperature located at the sensor being used for modulation Use this option only with primary pumping that will be turned on from a remote source For example the water at the modulation sensor will stay warmer than the water at a heat terminal receptacle air handler etc This will cause an undesirable delay for the system pump to carrying heat to the building ODisable This option will prevent the boilers from providing heat for the system Setpoint source Local Set this value to S2 J8 6 4 20mA OS2 J8 6 4 20 mA for remote setpoint The S2 J8 6 4 20 mA sensor will need to be setup in the Sensor Configuration Page to enable remote setpoint Setpoint 180 F SAA Time of day setpoint 120F SAA 4 mA water temperature 100 F This value represents the setpoint when the remote signal is 4 mA These values become the low point of the linear remote setpoint curve 20 mA water temperature 180 F This value represents the setpoint when the remote signal is 20 mA These values become the high point of the linear remote setpoint curve Demand switch OEnabled Disabled The source of DHW loop control can be specified to use different inputs Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 51 Form 2396 Date 2 27 2015 Insta
70. ion pages ends the scope of the password entry The user is notified that a new password is needed upon the first attempt to change a parameter or until a password is entered successfully The user can continue viewing the configuration parameters regardless of whether a password is entered successfully The boiler also maintains a password timeout that limits the scope of the password entry Once a password is successfully entered the boiler starts an internal timer that expires after 10 minutes of inactivity After the timer expires the user is required to re enter a password before a parameter can be changed The user is not required to enter a configuration password for a parameter that has a lower access level than the access level achieved by an earlier password entry for any configuration group as long as the user stays in the configuration pages The user only needs to enter a password once until a parameter that has a higher access level is selected The user enters the password from a keyboard as shown in Figure 13 After the password is entered select the OK button The Cancel button aborts the password login warnine Explosion Hazard Improper configuration can cause fuel buildup and explosion Improper user operation may result in PROPERTY LOSS PHYSICAL INJURY or DEATH Changing parameters must be attempted by only experienced and or licensed burner boiler operators and mechanics Three le
71. iring and correct any possible errors 2 Replace the stack sensor 3 If previous steps are correct and fault persists module replace the 96 Outdoor fault sensor 1 Check wiring and correct any possible errors 2 Replace the outdoor sensor 3 If previous steps are correct and fault persists replace the Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 41 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Code Description Recommended Troubleshooting of Lockout Codes Code module 105 Flame detected out 1 Check that flame is not present in the combustion chamber H or L of sequence Correct any errors 2 Make sure that the flame detector is wired to the correct terminal 3 Make sure the F amp G wires are protected from stray noise pickup 4 Reset and sequence the module if code reappears replace the flame detector 5 Reset and sequence the module if code reappears replace the module 106 Flame lost in MFEP 1 Check pilot valve Main Valve for DSI wiring and operation L 107 Flame lost early in correct any errors L run 2 Check the fuel supply 108 Flame lost in run 3 Check fuel pressure and repeat turndown tests L 109 Ignition failed 4 Check ignition transfor
72. ize of the boiler They are not intended for alcove installation and are suitable for installation on non combustible flooring only Adhere to all applicable local codes regarding boiler installation and clearances 1 2 1 Minimum Clearances to Combustible Surfaces Figure 1 Minimum Clearances C Triple Flex DIM Description 150 300 A Clearance Above Top of 18 Boiler B Right Side 18 From Chimney or Vent C Collector Measured 18 Horizontally Left Side Tube Access D Side On Standard 27 Construction From Chimney or Vent E Collector Measured 18 Vertically F Front of Boiler Gas Train 48 amp Control Panel End Rear of Boiler Opposite G Gas Train amp Control Panel 18 End Table 1 Minimum Clearance 1 3 Receiving the Boiler The boiler is shipped from the factory with 4 shipping feet legs bolted to the skids These are provided to facilitate unloading moving with a forklift Lifting lugs are also provided to enable Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 2 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 over head lifting The shippin
73. k wiring for any loose neutral wires L 2 Check Preignition Interlock switches to assure proper functioning 3 Check the valve operation 4 Reset and sequence the module monitor the PII status 5 If code persists replace the module 67 ILK OFF 1 Check wiring and correct any possible shorts L 2 Check Interlock ILK switches to assure proper function A1 Low Water A2 High Burner Temp Refer to section 2 4 1 A4 High Gas Pressure Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 40 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Code Description Recommended Troubleshooting of Lockout Codes Code Low Gas Pressure Low Pilot Pressure High Air Exchg Pressure High Burner Pressure Air Flow Switch 3 Verify voltage through the interlock string to the interlock input with a voltmeter 4 If steps 1 3 are correct and the fault persists replace the module 68 ILK ON This lockout occurs when the interlock string is closed before the blower starts The airflow switch is the only device in the interlock string that will open when in standby Probable causes are 1 Air pressure in the boiler room has become negative 2 Excessive downdraft in the stack 3 Blower is spinning before being comman
74. lay el ae Figure 33 Reset Reboot Display A reset of the display may be needed when information on the screen is missing or appears to be wrong The display can be reset or rebooted without powering down the boiler Select the Yes button and the display will reboot as outlined in paragraph 2 2 1 2 2 18 Rename Control el gt Setup gt Control Setup gt Rename Control The name of the boiler can be changed to show a more appropriate name by using the onscreen keyboard For example Best Middle School Boiler 1 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 28 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 2 19 Outdoor Reset ALE Configure gt Sensor Configuration eos f gt E gt Configure gt Outdoor Reset Configuration Bryan Steam Sensor Configuration N g kl S1 38 4 sensor Inlet or Return UNCONFIGURED S2 38 6 sensor 4 20mA remote UNCONFIGURED S5 J8 11 sensor 10K NTC single non safety S6S7 19 1 3 sensor DHW UNCONFIGURED ele Outdoor temperature source S5 J8 11 sensor Figure 34 Outdoor Reset Sensor Configuration The following parameters must be set per Figure 34 There must b
75. limiting orifice Figure 7 item 26 if the O2 is not within 6 to 10 Final adjustments for NOx O2 and CO should be made at the maximum firing rate No further adjustments are required of the gas limiting orifice valve Return to the minimum low fire rate paragraph 2 2 13 in increments of 500 rom For each increment verify combustion readings Refer to trouble shooting paragraph 2 4 for further help NOTE Use rpm values that fall between the rom values used going to high fire This will give more points to verify on the modulation curve 2 3 9 Adjusting Boiler Minimum Input NOTE The boiler maximum input must be adjusted before final adjustments can be made for minimum input Decrease the boiler firing rate to the minimum modulation rate paragraph 2 2 13 Adjust the O2 level within 6 to 10 to obtain desired NOx O2 and CO levels by adjusting the low fire displacement on the gas pressure regulating actuator Allow sufficient time for combustion to stabilize after each 1 4 to turn of the low fire displacement Figure 7 item 2 Boiler Model TF300 TF250 TF200 TF150 Pilot Gas Pressure 3 5 4 3 5 4 3 5 4 3 5 4 IWC Light Off 1800 1800 1200 1200 High Fire Gas Fumace Les 29 3 4 22 Pressure IWC Gas Manifold 44 3 6 4 0 2 0 Pressure IWC 6000 5100 3550 2700 Max RPM 7999 5500 4200 2850 Low Fire Gas Manifold 3 3
76. ll help to protect this equipment from damage by such debris In combination with system contamination bacteria from ground water boiler water may produce objectionable odors sometimes resembling the odorant used in natural gas It is important to keep these fumes from air intakes that would distribute them throughout the building warnine The boil out procedure outlined must be performed by or under the direct supervision of a qualified technician The chemicals used present a hazard of burns and physical injury if mishandled Always use a suitable facemask goggles protective gloves and garments when handling caustic chemicals Do not permit the chemical to come into contact with skin or clothing Always follow the safety precautions on the container s label Add chemicals slowly and in small amounts to prevent excessive heat and agitation The boil out of the boiler and system is neither difficult nor expensive The chemicals needed for cleaning are readily available Tri sodium phosphate and sodium hydroxide lye are the most commonly used chemicals Be certain the chemicals used contain NO CHLORIDES Use only one type of solution in the system The amount of chemical required will vary according to conditions but one pound per fifty gallons of water is suggested Fill the system with this solution venting all air Then with the circulating pump running bring the system to design or operating temperatur
77. llation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 Parameter Value Notes Setpoint 50 195 F SAA Time of day setpoint 50 195 F SAA Priority source ODHW heat demand Disabled DHW heat demand Disabled Priority method Boost during priority time ODrop after priority time Boost during priority time drop after priority time DHW priority override time hour min s If this parameter is non zero then a DHW demand will take priority over other demand sources for the specified time If this persists for longer than this time the priority will expire The timer is reset when demand from the DHW source turns off DHW has priority over CH CH gt DHW DHW gt CH SC Override Time EE This parameters determines the priority of DHW versus the CH call for heat when both of these are enabled and active If DHW has a lower priority it may be boosted to the highest priority temporarily via the DHW Enable OEnabled Enable this parameter to protect the Disabled system from freezing when there is no building demand For example someone forgot to enable the remote STAT Outdoor setpoint 32 F The outdoor temperature when the system should come on Frost protection rate 20 The firing rate to maintain until the outdoor temperature is 4 F above the outdoor setpoint Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765
78. m 2396 Date 2 27 2015 Revision 3 you to the home page sa Figure 12 Home Page Pressing the boiler icon allows the user to zoom in on the boiler and see specific details about it These details are provided on a new page which can include additional buttons that display additional detail and operation information which itself leads to other pages The pages are traversed in a tree structure method The boiler icon button will appear in one of four colors indicating the boiler status N Blue Normal operation Red Lockout condition N Gray Standby mode burner switch off e Gray and crossed out Hydronic control communication error disconnected or powered off Pressing the Setup button on the Home page displays miscellaneous display setup and diagnostic functions 2 2 3 Page Navigation The System Display Figure 3 item 5 presents information and options in a paged manner Pages are displayed in a tree structure in which the user navigates up and down to arrive at the desired function The page descriptions are provided below so that you can understand the purpose of each and view the selections parameters and information that are available or required on each Most pages have a Home button in the top left corner of the screen and a Back button in the top right corner of the screen The Home button returns the user to the Home page and terminates any operation in progress The Back button D re
79. mer electrode flame detector flame L detector setting or flame rod position 5 If steps 1 through 4 are correct and the fault persists replace the module 1 Something has fell down and is partially obstructing the ignition tube 2 Someone has increased the pilot pressure above 4 iwc This would cause a carbon hair to form over a short time and break off when the unit is reset 3 The igniter gap needs to be adjusted 1 8 has been found to work the best The diameter of the pigtail could be too large causing the spark to spark off of the inside pipe wall instead of the screw 4 You may have a cracked igniter 122 Lightoff rate 1 Check wiring and correct any potential wiring errors L proving failed 2 Check VFDs ability to change speeds 123 Purge rate proving 3 Change the VFD L failed 4 If the fault persists replace the module Note This is an abbreviated list of lockout and hold codes For a full list of lockout and hold codes refer to the Honeywell R7910A manual Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 42 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 2 4 3 Alert Codes Table 16 Alert Codes Code Description 29 Burner switch was turned OFF 30 Burner swit
80. mit access to the primary air to air exchanger Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 16 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 2 1 5 Triple Flex Behind the Cabinet OTE a Door The supply pressure is not Static The supply pressure is measured at the maximum full flow of gas through all gas burning equipment tied to 14 15 16 17 18 30 19 the main service line 31 13 33 12 11 10 w Q ono o ho 29 Figure 7 Triple Flex Behind the Cabinet Door 1 2 The low fire displacement final adjustment valve actuator Step down regulator decrease gas flow NOTE should be made at low fire only 3 valve actuator the air to gas ratio irrespective of air volume changes minimum of 14 inches of water column must be supplied at the gas inlet connection Figure 6 item 1 The supply pressure can be measured at the test port Figure 7 item 28 Auxiliary gas pressure regulating and shutoff Low fire displacement adjustment that can be adjusted by removing the cap and rotating the slotted screw clockwise to increase gas flow and counter clockwise to Main gas pressure regulating and shutoff The pressure regulating actuator provides slow opening fast closing safety shutoff and air gas rat
81. n Triple Flex boilers have the ability to function as a stand alone boiler management control A Lead Lag Master control uses the Sola portion of the Master control to function as one of the slaves Table 17 is a list of parameters with factory default settings The default settings are a starting point for setting up the lead lag system and for most applications will be adequate Some applications may require different parameter values The table also gives a brief description of the options for each parameter 4 2 Lead Lag Sequence of Operation All stages that are Firing receive the same firing rate Only the Base load common parameter is used for base loading the individual slave s base load values are ignored As load increases until all stages are firing no stage is requested to exceed the common base load rate After all stages are firing there is no restriction on the slave s commanded firing rate As load decreases as long as all available stages are firing there is no restriction on the slave s commanded firing rate When at least one stage has been dropped no stage is requested to exceed the common base load rate 4 3 Lead Lag Communication Bryan Steam provides RJ 45 connection ports on each boiler to facilitate daisy chaining the boilers together Figure 49 Should a separate device be used as a lead lag controller and uses Modbus RTU communication protocol it can be directly connected into t
82. nd Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 A motorized damper or louvers shall be interlocked so the burner s cannot operate unless the damper or louver is in the fully open position 1 7 2 3 Mechanical Combustion Air Supply When combustion air is supplied by mechanical means an airflow sensing device shall be installed and wired into the safety limit circuit of the primary safety control to shut off the gas in the even a an air supply failure 1 7 2 4 Appliance Venting per CAN CSA B149 1 05 Paragraph 8 9 of CAN CSA B149 1 05 addresses Appliance Venting Paragraphs 8 9 through 8 31 address many facets of flue gas vents many of which do not apply to the Triple Flex boiler which is a Category IV listed appliance requiring the use of special venting systems as previously described NOTE Please note that the information provided in this manual relative to the Canadian Standard is not meant to be all inclusive Reading the entire Standard is strongly suggested The final approval of all system designs must be acceptable to the authority having jurisdiction e Venting for Category IV appliances shall be as specified or furnished by the manufacturer of the listed appliance The Triple Flex boiler is a Category IV appliance requiring the use of special vent that is certified e A special venting system shall be installed in accordance with the
83. nd the flue collector sleeve to prevent distortion from heat If a new burner is proved by the factory it will have all the required insulation pieces installed Check to be sure that the internal dead band insulation and retainer band have not slid forward during shipment The correct position is tight to the raised ring on the flange end of the burner Check the blanket insulation around the burner The insulation around the burner should be tight against the external dead band insulation Pack blanket insulation into any gaps present Note When the boiler is supplied with a castable refractory the external dead band insulation should be not have any damage resulting in any voids between the burner and the refractory Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 39 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 2 4 2 Lockout and Hold Codes To support the recommended Troubleshooting the R7910 has an Alert File Review the Alert history for possible trends that may have been occurring prior to the actual lockout Note Column H Hold message L Lockout message H or L either Hold or Lockout depending on Parameter Configuration Table 15 R7910A Lockout and Hold Codes Code Description Recommended Troubleshooting of Lockou
84. nformation from each boiler about the access level settings for the status and configuration parameters The installer and OEM passwords can be changed in the boiler after logging in with the current password When the password is changed at the S7999B1026 it is saved in the R7910 and effective for all future logins NOTE Each boiler in a multi boiler configuration has its own set of installer and OEM passwords To avoid user confusion the passwords should be changed to the same setting in all the boilers but there is no requirement to do so 2 2 8 Change Parameter Settings A Setpoint Burner enable ON 195 g A 180 et efel Central Heat Jop Normal 50 Time Of Day o i a i 2 s s slelzlel Figure 17 Change Parameter Dialog Change parameter settings by selecting the parameter on the page A dialog box displays for the parameter with controls allowing the user to change the value Figure 17 After changing the setting to a new value press the OK button Pressing the Cancel button leaves the parameter unchanged The changed setting is reflected on the screen and sent to the boiler when the OK button is pressed There are two classes of parameters Non Safety Non safety parameters can be changed without placing the boiler in a dangerous state These parameters typically do not require a password to modify Safety Safety parameters can b
85. nical Code Fuel Gas Code ANSI warnine Do not locate air intakes where petroleum distillates CFC s detergents volatile vapors or any other chemicals are present Severe boiler corrosion and failure will result 1 7 Flue Gas Venting System Triple Flex boilers are Category IV appliances that vent with a positive exhaust vent pressure and with a temperature that is likely to cause condensation Any venting system used with the Triple Flex boiler must comply with the requirements for Special Gas Vents per UL Category Code CCN DGSH which are UL Listed per UL 1738 or UL Category Code DGSH 7 which are cUL Listed Canada per UL 1738 warnine The Triple Flex boiler is NOT certified for use with other types of venting excepting Special Gas Vents Use of any other types of venting may cause vent failure resulting in serious injury or death 1 7 1 Design amp Installation A qualified venting professional experienced in venting system designs should design the boiler vent system The vent size must be NO LESS THAN 8 IN DIAMETER and sized such that the pressure drop between the boiler and the point of discharge does not exceed 0 20 WC While the vent must be UL Listed Special Gas Vent per Category Code DGSH or DGSH7 for Canada Bryan Steam LLC recommends the use of venting components fabricated from AL29 4C material The vent installation must be in strict compliance with the
86. nnections Connection s to an expansion tank are to be provided by others in the system piping separate from the boiler 1 4 4 Drain Connection A drain valve must be installed on the boiler drain connection the same pipe size as this connection to allow draining of the boiler 1 4 5 Condensate Drain Connection A 1 MPT connection is provided to drain the condensed products of combustion from a condensate trap located beneath the boiler This must be run to a drain using stainless steel The condensate temperature should never exceed 212 F and the pH of the condensate should never have a value lower than 3 5 NO VALVE is to be installed in this line from the boiler to point of discharge Note An external ball type trap may be required for operating water temperatures greater than 160 F return and 180 F supply or ambient supply air temperatures greater than 100 F 1 4 6 Gas Supply Connection The installation must conform completely to the requirements of the authority having jurisdiction or in the absence of such requirements shall conform in the U S to the current National Fuel Gas Code ANSI Z223 1 1984 or in Canada to the current Natural gas and propane installation code CAN CSA B149 1 05 and applicable regional regulations for the class which should be followed carefully in all cases Authorities having jurisdiction should be consulted before installations are made 1 4 7 Drip
87. nts sticking and leaking Frequent relief valve operating Piping leaks at joints IRN American Boiler Manufacturers Association ABMA 2005 Boiler Water Quality Requirements and Associated Steam Quality for Industrial Commercial and Institutional Boilers 1 10 2 Objectives The basic objectives of water treatment are Prevent the accumulation of scale and deposits in the boiler Remove dissolved gases from the water Protect the boiler against corrosion Maintain the highest possible boiler fuel efficiency Decrease the amount of boiler down time from cleaning 1 10 3 Water softener It is highly recommended that a zeolite water softener be used for all make up to the boiler It is intended that this be used in addition to the chemical treatment of the boiler Water softening removes calcium and magnesium the primary causes of hard boiler scale 1 10 4 Continuous monitoring required Water treatment should be checked and maintained according to Table 8 whenever the boiler is operating The boiler operator should be sure that the boiler is not operating for long periods without proper water treatment Water treatment may vary from season to season or over a period of time Therefore the water treatment procedure should be checked not less than four times a year and possibly more frequently as the local water conditions may indicate It should be noted that water boilers may well need chemi
88. o less than the minimum and no more than the maximum specified in Table 5 for each Triple Flex connected in the system Minimum Flow Maximum Flow Rate Rate Model High Low High Low gpm Fire Fire gom Fire Fire AT AT AT AT TF300 54 100F 20F 270 20F 4F TF250 45 100F 24F 225 20F DE TF200 36 100F 20F 180 20F 4F TF150 27 100F 27F 135 20F DE Table 5 Water Flow Rates for Variable Primary Pumpin warning Do not use this table to size a constant volume pump Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 5 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 1 5 4 2 Water Flow Rates Primary Secondary Systems Secondary Loop 4D max Existing Boiler Each Triple Flex connected to a secondary loop of a primary secondary pumping system shall have a constant volume pump sized in accordance with Table 6 20 FAT Flow 40 F AT Flow Rate Rate Model High Low High Low gpm Fire Fire gom Fire Fire AT AT AT AT TF300 270 20F AE 135 40F 8F TF250 225 20F 5F 113 40F 10F TF200 180 20F 4F 90 40F 8F TF150 135 20F
89. ockout Annunciation Figure 27 Operation Page The operation page displays the boiler running operation including set point and firing rate values From this page the user can change set points manually control the boiler s firing rate manually turn pumps on view annunciation information and switch between heating loops Central Heat and Domestic Hot Water as shown in Figure 27 2 2 12 Annunciation Page A E OPERATIONK ANNUNCIATION ECH Bryan Steam H gl Annunciation D D PII PII Proof Of Closure ON IK AL Low Water OFF A2 High Burner Temp OFF A4 High Gas Pressure OFF A5 Low Gas Pressure OFF A6 Low Pilot Pressure OFF a High Air Exchg Press OFF A8 High Burner Pressure OFF We Air Flow Switch OFF Figure 28 Annunciation Page The annunciation page shows the status of the load control input recyclable interlocks pre ignition interlock proof of gas valve closure and the running interlock strings The components are listed in the order they are wired This page can be called up at any time Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 26 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 from the operation page Figure 27 This page is very helpful for troubleshooting a lockout 67 ILK
90. off All components for a given string are wired in series The first component that indicates off will be the safety device to troubleshoot 2 2 13 Modulation Configuration Al Configure gt Modulation Configuration PAS Bryan Steam H Modulation Configuration D CH maximum modulation rate 6000 RPM x DHW maximum modulation rate 6000 RPM Minimum modulation rafe 1200 RPM Rate assigned to 0V 4mA 0 CH forced rate time 0 sec CH forced rate 1200 RPM DHW forced rate time 0 sec DHW forced rate 1200 RPM CH slow start enable Disabled el Figure 29 Modulation Configuration The modulation configuration page is used to set the modulation range of the boiler The recommended maximum and minimum rpm values can be found in Table 12 The maximum rpm rate can be used to limit a boilers maximum input in case there is not enough supply gas to operate at full input For multiple boilers all boilers should be limited so that when all boilers are operating there is a sufficient supply of gas for all boilers 2 2 14 Firing Rate Control Page el Ss Operation gt Firing Rate Box a Bryan Steam H Central Heat Operation Bee SE Kl Burner state Standby E Normal Demand Central Heat Time Of Day 1609F Firing rate C ORM e Source Normal Outlet sensor 77 F Annunciation Manual firing rate A li Heat an 1200 W RM O sare KaKaIEaaEs
91. ow voltage communications printed circuit board This board is used to daisy chain multiple boilers for lead lag and building automation communication Gas limiting orifice valve This valve is used to increase or decrease the gas air ratio for combustion Adjustments are made by removing the cap and using a flathead screwdriver Clockwise rotation will increase the flue outlet O2 levels and counter clockwise will decrease the flue outlet O2 level Starting point adjustments are listed in the table This valve is factory set and the number of turns out is written in black adjacent to the adjustment cap Turns Out From Bottom Poner After Before Model FEB 2015 FEB 2015 TF300 6 1 2 to 7 8 1 2 to 9 TF250 6 1 2 to 7 8 1 2 to 9 TF200 4 1 2 to 5 6 1 2 to 7 TF150 4 1 2 to 5 6 1 2 to 7 Table 10 Gas Limiting Orifice Rough Settings Main low gas pressure switch Manual 27 28 29 Reset This switch is not adjustable and is preset at 9 inches of water column Supply gas pressure test port 1 4 NPT Air pressure sensing line connection Possible Locations a Flue collector b UV scanner pipe Approx 4 14 c Blower inlet Approx 2 15 Air pressure sensing line connection Gas pressure sensing line connection Gas pressure sensing line connection Burner internal thermal fuse see section 2 4 1 2 1 6 Pilot Spark Igniter Assembly
92. r threshold temperature OFiring rate threshold ODisabled lead rotation time When this parameter is set to 0 it is disabled Any non zero value will be used for all slaves Effectively overriding the base load setting for all slaves and using a single value Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 54 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 Parameter Value Notes Detection time 20 min 60 min This parameter defines the time before a stage is added When the water temperature is below the setpoint by the amount set by the error threshold parameter and the firing rate is between the base load common rate and the rate offset the add stage timer will start When the time is equal or greater than the detection time another boiler will be added Error threshold temperature SF Set this parameter to the number of degrees below the setpoint to start the detection timer Rate offset 10 This is the percent offset from the base load common the firing rate will be at to start the detection timer 100 0 see Detection time for further explanation Interstage delay 5 min This is the minimum amount of time to wait before enabling another boiler This parameter may be hidden
93. ration Page paragraph 2 2 11 page 26 for more details Diagnostic Used to view R7910 diagnostic information Details Used to view boiler detail status information History Used to view R7910 history Modulation Used to toggle between two different status displays modulation and setpoints 2 2 6 Configuration Page el 8 CONFIGURE Bryan Steam Configuration Menu E Select Configuration Group System Identification amp Access CH Central Heat Configuration Outdoor Reset Configuration DHW Domestic Hot Water Configuration DHW Storage Configuration DHW Plate Heat Exchanger Warm Weather Shutdown Configuration Demand Priority Configuration E Ka Verify The configuration page allows the user to view and set parameters that define how the boiler functions in the hydronic heating system Configuration parameters for any boiler connected in the Global Modbus network can be accessed from the display Press the boiler s button on the Home page to access the Status page Pressing the Configure button on the status page starts a configuration session The configuration page contains a menu of parameters grouped into functional areas that the user selects for configuration see Figure 15 Figure 15 Configuration Menu Page No specific order for configuring the boiler is required All parameters are enabled for editing though some may not be applicable e g a configuration parameter may dis
94. rror threshold not enough information to determine the functionality All boilers off threshold Slave enable Unconfigured Enable slave for built in Lead Lag master OEnable slave for third party Lead Leave this value as is There is not enough information to determine the functionality Lag master ODisabled Slave mode Ouse first Ouse last Equalize run time Base load rate 3000 rpm This parameter is not used The slaves base load will be determined by the master Slave sequence order 0 This parameter has no effect when using equalize run time Enter a Sequence number when the slave mode is set to either Use first or Use last Demand to firing delay 7 min This parameter is the amount of time the boiler needs to fire the burner This will include 5 minutes for flame stabilization about 2 minutes for purge Add any time it takes to close all interlocks from dampers valves etc Fan rate during off cycle 0 rpm Not used Modbus port OMB1 OMB2 ONo port Modbus address 1 8 This value must be unique for each boiler Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com 56 Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 4 4 System Wiring Hookup IN OUT IN OUT PL SL
95. rs shall be interlocked with the appliance so they are proven in the full open position prior to main burner ignition and during main burner operation Means shall be provided to prevent the main burner from igniting should the louver fail to opening during burner startup and to shut down the main burner if the louver close during burner operation 1 6 2 4 Combustion Air Ducts Combustion air ducts shall comply with the following Ducts shall be constructed of galvanized steel or a material having equivalent corrosion resistance strength and rigidity Ducts shall terminate in an unobstructed space allowing free movement of combustion air to the appliances Ducts shall serve a single space Ducts shall not serve both upper and lower combustion air openings where both such openings are used The separation between ducts serving the upper and lower combustion air openings shall be maintained to the source of combustion air Ducts shall not be screened where terminating in an attic space Horizontal upper combustion air ducts shall not slope downward toward the source of combustion air For informational purposes there are several codes that address the amount of air and or size of the opening s in walls for combustion air NFPA 54 National 2223 1 ASME CSD 1 Controls and Safety Devices for Automatically Fired Boilers ASME Section VI Recommended Rules Tor Care and Operation of Heating Boilers BOCA National Mecha
96. ryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 20 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 2 5 Status Page CR amp Bryan Steam AQ Demand Central Heat Firing rate 100 Burner state Run Setpoint 180 F Outlet Stack Flame _ 75 F OPEN 11 07v Setpoints Pumps ON Modulation OFF Central Heat 165 F 180 F 182 F History Configure Operation Diagnostics Details Figure 14 Status Page The status page Figure 14 is displayed when the hydronic control is selected on the Home page The status page displays the current condition of the boiler and displays some of the more important configuration settings The boiler name is displayed in the title bar of the status page NOTE When the boiler has no name defined the display will use the Modbus address to identify the boiler The standard status page displayed for the Triple flex boiler contains summary status information as shown in Figure 14 Any status information not applicable for the installation is blanked out on the screen Buttons on this screen include Configure Used to configure the R7910 see Configuration Page paragraph 2 2 6 page 21 for more details Operation Used to perform daily frequent functions with the R7910 such as setpoint adjustment etc See Ope
97. s set This setting may be inhibited due to burner fault or disable Control Figure 43 Advanced menu Check Demand across from Central Heat if the contact needs to be on when the boilers are enabled and remain on until the boilers are disabled Check Local burner demand if the contact needs to be on when the burner is on and off when the burner is off a Select to return to the main screen Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 2 2 24 Performing High Limit Test ia el E CONFIGURE gt High Limits warnine Performing this test requires the resetting of a boiler safety limit It is extremely important that the setpoint be returned to its original value before leaving the boiler The purpose of the high limit test is to prove that the limit sensor and control will shut off the boiler if the outlet high limit setpoint is exceeded The high limit sensor for the Triple Flex is a dual element thermistor integral with the operating control sensor for the unit see 2 2 11 Note Login required see paragraph 2 2 7 Bryan Steam High Limits DHW high limit Disabled DHW high limit response Lockout DHW high limit setpoint 200
98. sassintsccceaseessatsaziisarsavedsantaonsinatcatesnceiutestvevssiousdsbvtesnes T E A a AEE 5 1 5 3 Combustion Air and FLUC Gas eeneg deiere EENEG 5 1 5 4 Pump and Piping Reouirements ENEE 5 1 5 4 1 Water Flow Rates Variable Primary Pumping Systems ENEE 5 1 5 4 2 Water Flow Rates Primary Secondary Systems EEN 6 1 5 4 3 Water Flow Rates Constant Volume Primary Pumping Systems EEN 6 1 5 4 4 Water Flow Rates for GLYCOL nee ENEE 6 1 6 Combustion Air Supply SyStern e eeseessesssesssecstesseesseestesseeseesneessesseensecneesseeseeeaeenesseesueestesaeentesseeseeaeeseeneeaneeaneeaes 6 1 6 1 Combustion Air Openings sssrinin aiana EENEG 7 1 6 1 1 Two Permanent Opening Method een 7 1 6 1 2 One Permanent Opening Method EEN 7 1 6 1 3 Mechanical Air Supply Systems ENEE ENEE ENEE 7 16 2 LOUVers Grilles aNd SCLECIS iavicicscidicacsieiseccosidicedecevescansia ciudescasactvaitvaddicusesebesdivndtacdsacandidciuddl Aiii 7 1 6 2 1 LOUVErS and Gries za bssssscacvieeteereareitsceinecactrasthteisdsneeantienntedatcagaetaatacsuis ant ee 7 e EN EE 7 1 6 23 Motorized LOuetesesaegeoen inina a EA 8 1 6 2 4 Combustion Air DUCS niian a chteduteubebane etal cel esiatebietscheshetadelucbackelbabtatutss 8 1 7 Flue Gas Venting System ie 8 1 7 1 Design ScInstallation ege dade ace ase EENS AE dE EE AE 8 1 7 2 Combustion Air and Venting Requirements for Canada EEN 9 1 7 2 1 Air Supply Requirements per CAN CSA B149 1 05 for Appliances having an input exceeding 40
99. se is provided to prevent or stop operation of the boiler ourner in the event that the sensor is exposed to a temperature greater than 425 F Prior to contacting the factory for a replacement fuse perform the inspection of the burner as indicated in the following instruction The fuse operation is one time that is it is not resettable If the fuse trips the metal fiber burner is to be removed from the boiler and inspected for any evidence of a hole in the woven metal fiber distortion of the metal inner supporting sleeve or a loosening of the metal fiber around the metal supporting sleeve Further it will be necessary to remove the combustion chamber door and inspect the stainless steel flue collector sleeve for any damage or deformation Note The flue collector sleeve is only present on those models that do NOT have a castable refractory internal ring Also make sure the orifice on the end of the pilot supply line is present and does not have any heat damage Contact the factory for a replacement fuse which will be shipped with a ferrule to secure the fuse in position Should it be determined that there IS damage a new burner thermal fuse or any other damaged parts must be obtained from the factory When replacing the existing burner be sure that the external dead band insulation is in place and in good repair The part number for this material is P30234 Make sure that the blanket insulation is tight arou
100. stem piping must meet the requirements of local codes and jurisdictions Good engineering practices should be followed and considered for each piping system used It is advised that the circulating pump for each Triple Flex boiler be installed as close to the boiler as possible in the line to the return connection such that system water is pumped towards the boiler Installing circulating pumps for Triple Flex boilers so that the water is pumped away from the boiler is rarely recommended Means to eliminate air from the boiler piping systems is a must It is advised that an air separator be installed as close as practical to each boiler in the outlet pipe Further an air vent should be installed at all high points throughout the piping system It is recommended that a water meter be installed in the make up water system to the boiler system Scheduled recording of the water meter register will show an indication of a potential slow system leak in addition to providing insight into any system problems Also make up water as well as water for the initial system fill should be provided through a water softener Additionally chemical treatment of the system water is advisable Contact a qualified boiler water chemical treatment company for their recommendations See Section 1 10 for more information 1 5 4 1 Water Flow Rates Variable Primary Pumping Systems Variable primary pumping systems shall be capable of delivering n
101. t Codes Code 1 Unconfigured 1 New Device complete device configuration and safety L safety data verification 2 If fault repeats replace module 2 Waiting for safety 1 Device in Configuration mode and safety parameters need L data verification verification and a device needs reset to complete verification 2 Configuration ended without verification re enter configuration verify safety parameters and reset device to complete verification 3 If fault repeats replace module 49 24VAC voltage low 1 Check the Module and display connections H high 2 Check the Module power supply and make sure that both frequency voltage and VA meet the specifications 50 Modulation fault Check the absolute maximum fan speed in the fan configuration H This parameter must be equal or greater than other RPM parameters For example prepurge postpurge max modulation etc 52 Motor tachometer H fault 53 AC inputs phase Check the Module and display connections L reversed 2 Check the Module power supply and make sure that both frequency and voltage meet the specifications 3 On 24Vac applications assure that J4 terminal 10 and J8 terminal 2 are connected together 61 Anti short cycle Will not be a lockout fault Hold Only H 62 Fan speed not H proved 63 LCI OFF 1 Check wiring for correctness and loose connections H 2 Check Interlocks connected to the LCI to assure proper function 64 PII OFF 1 Chec
102. tor enters the wall ceiling or chimney The authority having jurisdiction must determine whether their area constitutes such a locality 1 7 5 Solid Fuel Appliance Vents Gas appliances shall not be vented to a vent or a chimney that serves a solid fuel burning appliance Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 10 Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 1 8 Before Placing Boiler In Operation 1 8 3 Boil Out Procedure 1 8 1 Cleaning The Boiler And System New Systems 1 8 2 Pre Boil Out Flushing Of System Much of the dirt and contamination in a new hot water system can be flushed out before the boil out of the system First flush the system of waste with clear water The boiler and circulating pumps must be isolated through the successive zones of the system to waste carrying metal shavings dirt pipe joint compound etc with it Follow with a chemical flush NOTE Be CERTAIN that the chemicals used to flush and boil out the boiler and system contain NO CHLORIDES The boiler is fabricated with austenitic stainless steels that can be severely damaged when exposed to chlorides The removal of pipe chips and other debris from the system before opening the isolation valves to the boiler and pumps wi
103. truction manual before attempting installation of or starting the unit Insurance and local or state regulatory codes may contain additional or more stringent requirements than those contained in this manual Installation must conform to these codes and any other authority having jurisdiction This instruction manual shall be posted and maintained in a legible condition 1 1 Boiler Foundation Before uncrating the boiler location should be prepared The boiler should set upon a good level concrete floor If the boiler is not level or the floor is not in good condition a concrete foundation should be built the dimensions being larger than the outside dimensions of the boiler base A 4 high housekeeping pad is suggested JAN warnine Do not install boiler on combustible flooring 1 2 Clearances See Table 1 for minimum clearances to walls ceilings or obstructions The clearances in Table 1 are intended as a general recommendation only Local codes must be applied to specific installations and the minimum clearances established accordingly Provisions must also be made for service accessibility and clearance for piping and electrical connections Do not obstruct combustion air and ventilation openings with piping or any other construction All boilers must be installed in a space that is large compared to the boiler NOTE These boilers should be installed in a room that is large compared to the s
104. turns the user to the previous page Two other icons may be noticed near the boiler name A bell will be displayed if the system is in lockout that reset will be required A padlock D will be shown on screens that a may need a password to change the parameter An unlocked padlock a indicates the password has been entered to change the parameter either the installer or OEM depending on the security level entered Selecting the padlock will allow the user to login with the appropriate password 2 2 4 Keyboard Figure 13 Keyboard Some pages request user entry of characters When this type of input is required a keyboard page appears as shown in Figure 13 The text box at the top of the screen displays the current or default setting of the user input The user can add to this text clear it or change it The Shift key on the left side of the screen shifts between upper and lowercase characters Pressing the Shift key toggles the keyboard from one mode to the other continuous pressing of the Shift button is not required The OK button should be pressed when the user is done entering the text input The Cancel button on the bottom of the screen allows the user to ignore any text changes that have been made and keep the original text value Pressing the OK or Cancel buttons returns the user to the page displayed prior to the keyboard page Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www b
105. ure This value is used to override the low water temperature of the curve created with the above points without changing the slope Outdoor boost time If CH outdoor reset is not active or if the CH ODR boost time parameter is zero then the boost function is inactive Otherwise the boost time provides a time interval and the other parameters must be valid if they are not Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 the boost function is inactive and an alert is issued Each time the boost time interval elapses and CH demand is not satisfied the effective CH setpoint is increased by the amount specified in CH ODR boost step Outdoor boost step Maximum effective CH setpoint Outdoor boost maximum off point Select the Show Line button to display a graphical representation for the inputted data Figure 36 The normal reset curve is shown in green and the time of day is red The blue line represents the absolute boiler water temperature the boiler will operate at AN CJ Bryan Steam D Central Heat Outdoor Reset 190 e FT Ke 180 170 160 150 140 130 120 110 100 a 0 o 10 20 30 40 50 60 70 Normal setpoint EZ Time of da
106. vels of write access to boiler parameters are permitted Each access level has defined rights when interfacing with configuration and status parameters in the Boiler e End user The lowest access rights no password login The end user can in most cases only read or view boiler parameters In some instances the end user can change boiler parameters e g change the CH central heat setpoint e Installer The next highest level The installer can read all boiler parameters and change most boiler parameters This access level is used to customize the boiler for a particular installation The default installer password is bryan e OEM The highest access level The OEM can read and change all R7910 parameters as well as change sensor limits and burner control safety parameters Different passwords exist in the boiler for each access level The end user level requires no password but the installer and OEM levels have unique passwords defined for them The display validates all password entry attempts with the boiler but doesn t conduct the validation itself The boiler has sole responsibility to accept a Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com 22 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 password entry The display gets i
107. vided The openings shall be open directly to the outside or ducted directly to the outside When directly open to the outside or ducted to the outside by_vertical ducts each opening or duct shall have a minimum fee open area of 1 in per 4000 BTU total input rating of the boiler s in the room If ducted to the outside through horizontal ducts each opening or duct shall have a minimum free area of 1 in per 2000 BTU total input rating of the boiler s in the room 1 6 1 2 One Permanent Opening Method One opening commencing within 12 of the top of the room shall be provided The opening shall be directly to the outside or shall be ducted to the outside with a horizontal or vertical duct The opening or duct shall have a minimum free area of 1 in 3000 BTU hour of the total input ratting of all appliances boilers in the room Not less than the sum of the areas of all_vent connectors in the room A vent connector is defined as the pipe or duct that connects a fuel burning appliance to a vent or chimney Additional area must be provided for other air consuming equipment in the room 1 6 1 3 Mechanical Air Supply Systems The combustion air supply may be provided by a mechanical air supply system If utilized the combustion air must be provided from the outside at a minimum rate of 0 35 ft min for every 1000 Btu hr input for all appliances located in the space If exhaust fans are utilize
108. y because although the boiler is hydrostatically tested at the factory minor leaks in fittings and at attachments can develop from shipping vibration or from _ installation procedures Replace tube access panels before proceeding to start boiler warnine It is often necessary to retighten such fittings after installation and after the boiler has been operated for some time 1 9 Draining and refilling the boiler amp system 1 10 Boiler Water Treatment If the system is drained and then refilled chemical treatment is essential to treat the raw water Use only clean softened water 1 10 1 Purpose of water treatment Water treatment is required for satisfactory Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Form 2396 Date 2 27 2015 Revision 3 operation of the boiler It must be devised to prevent depositing of scale and corrosion from acids oxygen and other such harmful elements that may be in the water supply A qualified water treatment chemist should be consulted and the water systematically treated Hot water systems must operate with a pH above 8 5 A system that has a pH below 8 5 will usually develop the following problems Gas formation air trouble Pump seal and gland problems Air ve
109. y setpoint Maximum Outdoor 60 F Low Water 100 F Minimum Outdoor 0 F Minimum Water Figure 36 Outdoor Reset Curve AlE CONFIGURE gt CH CENTRAL HEAT CONFIGURATION gt page SETPOINT gt Setpoint Source S2 J8 6 4 20mA gt 4 mA water temperature MIN gt 20 mA water temperature MAX 2 2 21 Remote Modulation 4 20 mA as j ALE Configure gt Sensor Configuration gt Sensor S2 J8 6 sensor gt Connector type 4 20mA gt SAFETY VERIFICATION paragraph 2 2 9 2 2 20 Remote Setpoint 4 20 mA el 8 Configure gt Sensor Configuration gt Sensor S2 J8 6 sensor gt Connector type 4 20mA gt SAFETY VERIFICATION paragraph 2 2 9 Note System verification paragraph 2 2 9 will need to be made to accept the changes made to the sensor configurations Note System verification paragraph 2 2 9 will need to be made to accept the changes made to the sensor configurations Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail inquiry bryansteam com Form 2396 Date 2 27 2015 Installation and Operation Service Manual Triple Flex 150 200 250 amp 300 Revision 3 lal x CONFIGURE gt CH CENTRAL HEAT CONFIGURATION gt page Modulation Note The boiler will shut down on high limit if not turned off remotely when the

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